How to Prepare Micro-Coils for Medical and Electronics Field?

When it comes to preparing some critical devices, such as transformers, electromagnets, inductors, or medical sensors, the development of micro-coils becomes essential for these devices. Micro-coils or electromagnetic coils are necessary for any type of application that requires collaboration between an electric current and a magnetic field.

There are mainly two methods to develop a collaboration between the magnetic field and the electric current, such as a) an electric current can produce a magnetic field while passing across an electrical conductor, b) an external magnetic field can produce an electric current while passing across the inner surface of an electromagnetic coil.

In order to produce the micro-coils, the winding process is essential that encompasses the winding of the wire and provides the shape into a coil, helix, or spiral. Based on the area of application, micro-coils can be of different shapes and dimensions. The other factors that also play a crucial role to determine the shape and size of the coils are magnetic field strength, desired resistance, and inductance. Even though there is a quite similarity between the regular coils and micro-coils, the basic difference is the tiny shape. Due to this tiny shape, manufacturers require a microscope or magnifying glass in the production process of micro-coils.

Challenges Because of Miniaturized Size:

Manufacturers place the electromagnetic coils or micro-coils into tiny medical devices or other small-sized devices. To deal with this physical size constraint, there is a huge demand for tiny micro-coils. In fact, micro-coils have to be smaller than a needle’s cross-sectional area. This tiny size of the electromagnetic coils is essential so that these coils can become useful for the microscopic parts of the sensors and transducers.

Challenges for Manufacturing:

In order to the micro-coils with the tiny size, manufacturers require to use ultra-fine wires that have a diameter of fewer than nine microns. During the manufacturing process, manufacturers also require connecting and winding these wires. Connecting and winding the ultra-fine wires is quite challenging.

How to Connect the Ultra-Fine Wires?

To build a connection between two ultra-fine wires, traditional methods are not useful due to numerous drawbacks. Thanks to thermal compression bonding technology that has significantly helped modern manufacturers to connect these wires. Whether the diameter and material of the wires are similar or different, you can rely on this technology for each case. This technology is also reliable to provide corrosion-free and strain-free joints. As this technology helps the manufacturer to increase the longevity of the micro-coils, therefore, manufacturers use this efficient technology to produce long-life products as well as disposals.

How to Wind the Ultra-Fine Wires?

The manufacturers wind or twist the electromagnetic coils around a core using the winding method and give the shape of a helix, coil, spiral. In order to conduct the winding process by maintaining the quality standards and tight tolerance needs, manufacturers need built in-house machinery.

Applications:

Micro-coils or electromagnetic coils have an enormous number of applications in the electronics and medical field, such as pain management devices, electrophysiology treatments, deep brain stimulation components, orientation and navigation sensors, pace-makers, electricity-based ablations, orthopedic and dental treatments.

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