Custom Flat Wire Coils

Our custom flat wire coil winding capability at Precision Econowind allows us to create coils for industries that require high performance in demanding environments. By using flat wire, the turns can be packed more closely, providing a greater flux density. In addition, flat wire is capable of dissipating heat more rapidly enabling flat wire coils to handle more power than their round wire counterparts. Flat wire coils may be edge wound or wound on the flat. Copper or aluminum wire may also be used.

Flat wire from #32 AWG to #16 AWG can be used to create coils with an inner diameter from 0.25” to 10.0” while maintaining tolerances as tight as ±0.001”. Finishing capabilities, including lead wire stripping and tinning processes and end connector assembly, are available to ensure that coils are complete and ready to be used by the customer. Flat wire coils are used extensively in the voice coil industry and in other applications that require high temperature performance and the most effective use of available space. Electrical testing including resistance turns count, and inductance testing is provided to ensure that coils meet all customer specifications. For more information about our custom flat coil winding capability, see the table below, or contact us directly.

CUSTOM FLAT WIRE COILS CAPABILITIES

General Capabilities
Custom Designs (Customer provided)
Contract
Production
Small Parts
Precision Layered
Coil Shape
Edge Wound
Flat Wound
Coil Winding Process
Flat Wire (Edge Wound or Flat Wound)
Free Standing or Bobbin Wound
Single Layer
Multi-Layer
Wet Wound
Bifilar Windings
Multifilar Windings
Dual Coils
Quad Coils
Wire Material
Copper
Aluminum
Wire Shape
Flat
Ribbon
Insulation Material
Low Temp (155°C)
High Temp (220°C)
Max Adhesive Temperature Rating
> 220°C
Max Adhesive Temperature Rating
> 220°C
Wire Size (AWG)
#16 to #32 AWG
Coil Winding Minimum Inner Diameter (ID)
0.25” – 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
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