Design and Engineering

Custom Coils is more than just a coil manufacturer. We partner with our customers and provide support from initial design, product development, prototype, and testing to full production release. This allows us to deliver the highest possible quality while lowering costs through process optimization planning and design for manufacturability analysis.

We pride ourselves in providing support and expertise to achieve our customer’s unique and challenging design requirements. We are the best resource to support coil design projects requiring tight space constraints, high thermal challenges, unique geometries, unusual cross-sections, and other functional and performance parameters with a focus on design for quality, manufacturability, and cost. Our customer-centric focus has facilitated the development of several long-term customer relationships, and is exemplified by the many products we have continued to support in production for over 20 years.

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Types Of Coil Designs Manufactured

At Custom Coils, we can design and manufacture coils with a variety of winding types depending on your particular needs. The type of winding you choose depends on various factors, including the number of turns, size and dimensional constraints, electromagnetic field requirement, power constraint, high or low frequency, and more. Because of this, it’s important to consider the particular requirements of your application to ensure the right coil design.

Coil Design & Engineering Industry Applications

At Custom Coils, we can deliver custom and specialty coils to meet the needs of various industry applications. Industries we serve include:

Medical

In the medical industry, coils can be found in therapeutic systems used to treat cancerous tumors as well as imaging technology such as MRI scanners. Some common types of coils found in the medical industry include steering coils, induction coils, and quad coils for uniformity of field.

Military

Electromagnetic coils are used in military applications such as missile defense, radar and radio frequencies, high-velocity electromagnetic rail guns, communication systems, and more.

Imaging & Scanning

Coils, inductors, and electromagnets are essential to several imaging and scanning applications, including imaging mass spectrometry (IMS), magnetic particle imaging, magnetic resonance (MR) spectroscopy, and MRI machines.

Semiconductor

Coil assemblies and electromagnets are utilized in a variety of processes that are part of semiconductor production. These include dielectric etching, ion implantation, metal deposition, and HDP-CVD and PECVD processes.

Aerospace

Coils are used in several ways within the aerospace industry, including altitude control, compass calibration, spacecraft thrusters, and earth observation. Because of the harsh environmental conditions present in this industry, coils must be manufactured with the utmost precision.

Power Generation

Wire coils can be found throughout a wide range of power generation applications, including wind turbines, hydroelectric turbines, combustion gas turbines, and steam turbines.

Custom Coil Materials Used

Custom Coils works with many coil materials to suit different industry needs. We understand that our coils are used in a variety of critical applications; therefore, we work with materials designed to hold up under harsh environmental conditions while ensuring optimal performance.

When designing and manufacturing our electromagnetic coils, we collaborate with our customers to understand their unique requirements and offer solutions based on our years of experience using various materials with high electrical conductivity, including:

Copper Magnet Wire
Hollow-Core Conductor
Litz Wire
Copper-Coated Aluminum
Copper Tubing
Aluminum Alloy
Copper-Beryllium

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Custom Coil Design & Engineering Capabilities

Services	Design Conceptualization Functional / Performance Parameters Electrical and Mechanical Design Prototype Development Project Management Engineering Consulting Tooling Development
Design Services	Critical Coil Design Parameters Material Specification and Selection Design for Manufacturability and Assembly CAD Modeling Rapid Prototype Development Process/Mfg. Tooling Cost Optimization
Design Considerations	Field/Inductance Matching Power Constraints Thermal Impact Physical Parameters Operational and Environmental Requirements Coil Finishing Requirements
Prototype Development	Audit/Scrub Drawings Procurement of Materials and Tooling Fabrication of Prototype Unit(s) Process Improvement Studies Test Plans First Article Inspection System Integration
Project Management Services	Technology and Project Feasibility Analysis Cost Estimating and Risk Assessment Design Review Quality Assessment Configuration Management Continual Process Improvement Scheduling and Program Tracking Manufacturing Process Outlines (MPOs) Inventory Management Prototype to Production Transition Management
Analysis	Coil Modeling Thermal Modeling Design for Manufacturability
Design Requirements	Parameters Order of Priority Preliminary Sketch Prototype Proposal / Plan Production Timing / Plan
Engineering Disciplines	Electrical Quality Assessment Material Sciences Mechanical Physics
Coil Types	Air Core Bobbin Wound Field RF Match Water-Cooled Self-Supported
Products	RF Coil Assemblies Chokes Electromagnets Focusing Magnets Inductors Solenoids
Testing	On-Going / Continual High Pot Inductance Resistance Leak Surge Thermal Standard Field Mechanical
Inspection	First Article

Additional Information

Industries Served	Semiconductor Equipment Processing Medical Energy Storage Power Generation High Energy Environmental Solar Security & Detection University Research
Intended Applications	Next Level Assemblies Power Supplies
Industry Standards	UL NEMA ISO Compliant
File Formats	CAD Capabilities 2D & 3D Modeling