Custom Coils, Inc.
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Six Coil Configuration, Connected in Series, Designed into a Flux Concentrator Assembly

Six Coil Configuration, Connected in Series, Designed into a Flux Concentrator Assembly
Six Coil Configuration
Six Coil Configuration, Connected in Series, Designed into a Flux Concentrator Assembly

Recently, Custom Coils collaborated with group of design experts on a project to build a complex Flux Concentrator Assembly. The elevated voltage holding requirements (approx 5000V from coil #1 to coil #6), and exposure to radiation required extensive modeling and analysis, in order to determine the optimal coil design and material selection . The need for radiation resistant consideration led us to the decision of using a kapton insulation around the conductor. Additional analysis was needed to determine the proper thickness required to meet the voltage holding objectives. With 2kA of pulsed current running into the coils, and a peak voltage of 8200V, it was clear that a significant cooling component was necessary. Through thermal modeling analysis, we determined that a hollow core conductor, in combination with a very precise machined form, featuring water cooled channels would allow average operating temperature to be maintained at 65 degrees F.

We designed the cooling form and all tooling/fixtures required to wind and assemble the coils. We developed a series of test parameters to ensure the final assembly would match the modeling analysis conclusions.

Ultimately, we were able to successfully build a prototype, which has been fully tested, and implemented. The outcome of this design allowed our customer to prove a concept, which is currently being designed into a new line of state of the art products available in 2014.

Highlights of this Coil Engineering and Design Project

Product Description
Six Coil configuration for Flux Concentrator Assembly
Coil Engineering Manufacturing Capabilities Applied/Processes
  • Product Development
  • Process Designing
  • Tooling Design
  • Test design

Prototype Manufacturing
Equipment Used to Manufacture Part
CNC Machine
Coil Winding System
Welding/soldering system
Industrial Oven
Overall Part Dimensions
12.25 ID x 19.5 OD
Tightest Tolerances
Material Used
.004 Kapton insulated magnet wire
High temperature epoxy
Nomex Insulating materials
Copper plate
Kapton lead wire
Material Finish
Kapton tape
Kapton wrapped hollow core conductor
Cooling form with water cooled channels, machined to wind coils and connect in series.
  • Maintained a constant operating temperature below 65 F
In process testing/inspection performed
Test Fixtures, Gauges, Functionality Testing
Thermal sensor
Industry for Use
R & D
Delivery/Turnaround Time
8 weeks
Delivery Location
San Jose, CA
Standards Met
Customer Specifications
Product Name
Hi Power Flux Concentrator Assembly