Introduction
Hello, this is PRONEC, a manufacturer and supplier of coils.
In this article, we would like to introduce our in-house air coil winding machine.
Air coils are widely used in familiar products such as smartphones, medical devices, and cameras. For companies aiming to move smoothly from prototyping to mass production, these coils must offer stable quality and efficient production capability.
This article will explain the basics of air coils, the key features of our equipment, and the benefits of our mass production system, in a way that is easy to understand from a specialist’s perspective.
What Is an Air Coil?
As the name suggests, an air coil is a coil formed entirely from copper wire without using molded parts or magnetic cores. It can take various shapes—round, oval, square, polygonal—providing high design flexibility. In English, it is often called a “Bobbinless Coil” or “Air Coil.”
At PRONEC, we mainly use hot-air fusion wire to manufacture air coils. By applying hot air during the winding process, the fusion layer of the copper wire melts, allowing adjacent wires to bond together into a single structure.
Air coils are typically fixed onto FPCs (flexible printed circuits) or molded components and then connected by soldering, making them widely applicable across electronic devices.
Features of PRONEC’s In-House Air Coil Winding Machine
At PRONEC, we have developed our own air coil winding machine to ensure stable quality and efficient mass production. Its main features are as follows:
- Fully Automated Winding for High Productivity
Once the copper wire is set and parameters are configured, the machine automatically winds the coils. Quantities can be preset, and the system can be integrated into a production line for smooth transfer to the next process.
Regular sampling inspections are performed to maintain quality. - Stable Quality with Servo Tension Control
The winding tension directly affects coil performance. By adopting servo tension control, we keep tension nearly constant during winding, minimizing variations in shape and electrical characteristics. - Compact Size for Easy Line Integration
Our winding machine is compact enough to be installed directly in production lines. This makes it easy to integrate with other processes and build an efficient production system.
Winding machine under construction
Factory Visits Deepen Understanding
In fact, many customers are not fully familiar with how air coils are manufactured. After seeing the winding process at our factory, we often hear comments such as: “Now I truly understand the structure, characteristics, and production methods.”
By observing the process firsthand, you can gain confidence in the reliability and potential applications of our coils. Please feel free to request a factory tour!
Conclusion | Prototyping and Mass Production with PRONEC
If you are considering prototyping or mass production of air coils, PRONEC can deliver stable quality and high efficiency through our in-house automated winding system.
For customers seeking overseas production, our Thailand factory can flexibly handle anything from small batches to full-scale mass production.
For factory visits or any inquiries, please feel free to contact us through our online inquiry form.