Custom Electrical Coils

Our reputation for quality and performance in the voice coil market has made Precision Econowind LLC an industry leader in custom electric coil manufacturing. Precision layered coils can be produced in a variety of round, rectangular, or custom shapes. Coils may be single or multilayer, wet wound with adhesive or dry wound, and freestanding or wound on a bobbin. Round wire or flattened wire can be used depending on space and cost requirements. These options allow for endless configurations to fit any application.

We use magnet wire made of copper, aluminum, or copper clad aluminum. Copper wire is typically used for its premium conductive properties. Aluminum wire can be substituted for weight-sensitive applications, or copper clad aluminum (CCA) wire can be used to reduce mass while retaining copper’s ease of soldering. Our proprietary high-temperature adhesive formulation allows coils to withstand temperatures upwards of 500 °F. This allows customers to place coils in tight spaces where ventilation is limited.

We work with inner diameters from 0.062” to 10.0” and wire gauges from #16 AWG to as small as #48 AWG. Inner diameter tolerances can be held to as tight as ±0.001” for smaller coils and ±0.003” for larger coils. Value added processes, such as stripping and tinning of the lead wires and end connector assembly, are available to create complete coils ready for installation. Electrical testing including resistance, inductance, and turns count testing can be performed to customer specifications. The typical lead time for a custom coil is 3 weeks, with additional time considerations required for specialized tooling. As a service to customers, we accept blanket orders and can maintain stock on customer items. For more information about our custom electrical coils, see the table below, or contact us directly.

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CUSTOM ELECTRICAL COILS CAPABILITIES

General Capabilities: Custom Designs
Contract
Production
Small Parts
Precision Layered

Coil Shape: Round
Rectangular
Flat Wire Wound as Single Layer Edgewound or Multi-Layer Flat Wound
Custom Shapes such as D-Shaped

Coil Winding Process: Single Layer
Multi-Layer
Wet Wound
Dry Wound
With Bobbin
Free Standing
Bifilar Windings
Multifilar Windings
Dual Coils
Quad Coils

Wire Material: Copper
Aluminum
Copper Clad Aluminum (CCA)

Wire Shape: Round
Rectangular (with rounded edges)
Flat
Ribbon

Insulation Material: Low Temp (155°C) High Temp (220°C)

Max Adhesive Temperature Rating: > 220°C

Wire Size (AWG): #16 to #48 AWG

Coil Winding Inner Diameter (ID) Range: 0.062” to 10.0”
Other sizes available with custom tooling

Winding Inner Diameter (ID )Tolerance (+/-): ±0.001” smaller coils
±0.003” larger coils

Added Value Processes for Coil Finishing: Stripping
Tinning
End Connector Assembly
Electrical Testing

Coil Winding Equipment: Manual Coil Winding Machines
CNC Coil Winding Machines
Soldering Irons/Posts
Soldering Equipment
Automated Stripping
Automated Tinning

Testing Equipment: Ohm Meters
Inductance Meters
Turns Counting Equipment

Testing Capabilities: Resistance
Turns Count
Inductance

Secondary Services: Assembly
Blanket Orders
Carrying Stock for Customers

Production Volume: Prototype
Small Run
Large Run

Typical Lead Time: 3 Weeks Typical
Additional Time Required for Tooling

ADDITIONAL INFORMATION

Industry Focus: Loudspeaker
Medical
Aerospace
Consumer Products
Industrial Components

Intended Applications: Solenoids
Voice Coil Motors
Space Constraint Applications

Industry Standards: ISO 9001:2015
ISO 14001
ISO 13485:2003

File Formats: PDF
Custom Sketches
Verbal Descriptions