Micro-coil winding process for medical sensors

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The most important rule when winding miniature medical sensors and standard sensors is that the wires should not touch each other, especially when wrapped around a core or some other shape. The first step is to insulate and coat the wire with insulation, then wrap it around a spindle. When the production unit follows this process, they create an induction from electromagnets. Whenever a manufacturer uses copper wires, they must insulate them. However, other materials used are normally resistant to voltage breakdown due to high temperatures. The winding process normally produces shaped coils.

What is the coil winding process for medical sensors?

The most important aspect of Winding process is its size. Coils used in medical processes, such as their insertion into veins, should be 0.8mm in diameter including insulation. To achieve this specialized production, a manufacturer must have uniquely designed machines. They make the most common coils from insulated copper wires and then wind them onto a spindle.

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For a manufacturer to stand out from the competition, their primary goal must be to produce the thinnest wound coil in the world. To do this, the coil must be less than 8 microns.

How do the coils differ from each other?

The main difference between these coils is their electrical value, caused by the difference in their sizes. What sets them apart are the shapes in which he wraps them: circular, rectangular or elliptical. Regardless of the shape of the coil, the innermost and outermost dimensions are the most crucial aspect of the coils.

What is the preparation process for creating micro-coils?

A manufacturer who intends to produce miniature sensors, their first step is to have the technical knowledge on how to wind miniature coils. The next step is to make sure that they have unique design machines that are not found in standard coil manufacturing or elsewhere.

A manufacturer must hire a specialized engineer to design and manufacture uniquely designed machines for the production of coils. They can’t buy the machines to make coiled coils because they don’t exist. The process of welding or producing miniature coils requires specialized design machines and can only be accomplished by creating machines that have been built by a manufacturer.

Manufacturers create miniature devices that are connective by using very fine wires to produce inductive components. Manufacturers achieve this by using more than one innovative technology. The technology they choose to use is based on the different methods used to process other metals or copper that is coiled up to the series size of 9 microns or 0.00035 inches. It is a delicate process to handle threads finer than a human hair, especially when the use of these threads must withstand various environmental factors.

You should expect that any manufacturer capable of producing these wound coils will be able to produce the devices that monitor the voltage and control the position of these wires. This manufacturer is expected to be the best in the field of producing miniature medical sensors.


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