Custom Electrical Coils

Our reputation for quality and performance in the voice coil market has made Precision Econowind Inc. 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.

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
TS 16949:2002
File Formats
PDF
Custom Sketches
Verbal Descriptions