Manufacturing of Micro-Coils

| Updated on February 26, 2024

Since the invention of small but incredible micro-coils, there has been a huge development in the field of medical sciences and technology. They gave life to millions of new possibilities regarding surgical operations and treatments. In the current time, they play a crucial role in performing surgery on the heart and other internal organs.

But have you ever wondered how these astounding Micro coils are made? We’ve brought to you a guide on the Manufacturing of Micro-coils. It explains the machinery requirements, challenges, production methods, and other important information.

What are Micro-Coils?

The creation of an electromagnetic coil involves wrapping any electrical conductor, like wire into the shape of a coil or spiral. There are various types of micro-coils, but every coil is specifically designed to tailor specific requirements. Their functionality doesn’t really differ from the regular coils, but they are incredibly small. It is often necessary to use a magnifying glass or microscope to examine and manipulate them.  

Electromagnetic coils are crucial for applications where an electric current interrelates with a magnetic field. The major applications of micro-coils are transformers, electromagnets, sensors, and inductors. In these applications, manufacturers either use an electric current to produce a magnetic field or use a magnetic field to generate an electric current.

Machinery Requirements for Winding of Micro-Coils:

You can not use your hands to wind the tiny micro-coils. To handle very tiny wires in the coil winding process, you require special machinery. You also have to rely on automated machinery to produce the micro-coils in huge quantities through mass production. The micro-coils can also be prepared with different geometrical shapes and types, such as jumble, orthocyclic, and helical.

Winding Method Challenges:

The biggest obstacle in the winding method is the size constraint. Manufacturers have to place the micro-coils into the tiny medical devices. Therefore, they need to wind the coils with ultra-fine wires which proves to be very challenging.

Dealing with ultra-fine wires is difficult for various reasons, such as:

  • The ultra-fine wires require proper insulation to evade reaching the breaking point.
  • There is always a limited space for the winding of the coils.
  • The machines should have high-speed manufacturing ability.
  • Curl wires are difficult to deal with.

Micro-Coil Winding Method:

The winding method is the basis of the manufacturing of the micro-coils. Through this process, an electrically conductive wire is wound in the shape of a spiral, helix, or coil. Different shapes and sizes are responsible for offering different inductance, resistance, and strength of the magnetic field. Thus, depending on your requirements for these parameters, you can also determine the desired shape and size. 

In the winding process, manufacturers are required to wind the coil with about 200 turns. However, as the coils need to be very tiny, thus, the manufacturers should minimize the thickness of the wire as much as possible. To deal with this, modern manufacturers use wires that are about 8 to 9 microns in diameter. 

Handling and connecting these wires is a very difficult job. When it comes to connecting two ultra-fine wires, you should always rely on thermal compression bonding technology. State-of-the-art methods and specialized equipment are also necessary for the winding process. 

Jumble Winding

Jumble winding, also known as scramble winding is a variety of winding in which a wire randomly wound on a bobbin. In this particular type of winding, the wire is not wrapped layer by layer with the presence of insulation in between. In fact, it is wound randomly until the number of turns has been reached. The sole insulation present throughout the process is provided by the insulation on the wire and the insulation on the bobbin. Cols wounded by this process are preferred in the manufacturing of electric motors and some other inductors. 

Helical Winding

For the preparation of a helix coil, the manufacturers have to create layers by switching directions. Therefore, the machines that can move forward and backward are effective for winding helix coils. However, for any type of micro-coil, ultra-fine wires are necessary, otherwise, with normal cables, the structure will become very tight after certain layers.

Orthocyclic Winding

The orthocyclic winding method is the most ideal method where the wire of the upper layer takes place in the channel of the wires of the lower layer. This manufacturing process helps to minimize the required space and makes the coil more efficient. This method is also helpful for the proper distribution of heat conditions and electric field strength. 

Conclusion

There’s no doubt in the fact that technology is changing healthcare for the better. From artificially intelligent Virtual Nursing Apps to Vein Visualization Technology or these super-incredible Micro-coils, the development has been reaching heights of success. 

The advanced ultra-fine micro-coils present an innumerable array of possibilities for engineers of compact medical equipment and other industries. During surgery, a surgeon is required to get at high-density areas with the least interference with regular body functioning. And these coils are just what they need!


Brayden

Education

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