Quality Coils manufactures custom coil assemblies that combine precision-wound electromagnetic coils with the terminations, connectors, housings, and other components required for integration into your finished products. By providing a complete assembly rather than a coil as a standalone component, we can help OEMs simplify manufacturing, reduce in-house assembly labor, and improve consistency from one production unit to the next.
Since 1965, Quality Coils has engineered and manufactured custom electromagnetic coils for demanding industrial, aerospace, defense, medical, transportation, energy, and specialty applications. Our vertically integrated manufacturing capabilities allow us to support the coil winding process as well as electrical connections, encapsulation, marking, inspection, testing, and light assembly.
Whether your project requires a custom solenoid coil assembly, tape wrapped coil assembly, self-supported coil assembly, encapsulated coil assembly, or another specialized electromagnetic assembly, our team works with your engineering and procurement teams to develop a solution that meets your electrical, mechanical, dimensional, and environmental requirements.
A custom coil assembly can incorporate much more than the coil itself. Quality Coils works with customers to determine the appropriate combination of coil construction, electrical connections, mechanical components, and protective materials for the application.
Our capabilities include:
Whether you are developing a prototype or need large-volume coil assembly manufacturing, our team brings decades of experience helping manufacture coil solutions for unique applications. Our integrated approach allows Quality Coils to manage the manufacturing in-house, maintaining control over quality and repeatability.
Not every application requires the same type of electromagnetic coil construction. During the design and manufacturing process, Quality Coils evaluates the electrical, mechanical, thermal, dimensional, and environmental requirements of the application to determine the appropriate coil configuration.
We incorporate a variety of electromagnetic coil constructions into custom assemblies, including self-supported, tape wrapped, and encapsulated. Custom assemblies can also be designed for specific applications, such as solenoid and actuator systems, where the coil must meet defined electrical, dimensional, and mechanical requirements. Our team of experts can review your system design and help advise on the right solution.
Custom Assemblies with Tape Wrapped Coil
Tape wrapped coils use insulating tape rather than a molded covering and can provide electrical insulation while allowing a flexible, cost-effective coil construction. Tape wrapped coils are commonly used in applications with relatively mild environmental conditions and may also be incorporated into assemblies where the customer will provide additional encapsulation as part of the finished product.
Quality Coils uses a range of tape products and insulation strengths to accommodate different electrical and application requirements. Tape wrapped coil assemblies can be configured with the appropriate leads, terminations, connectors, or other components needed for integration into your product.
Custom Self-Supported Coil Assemblies
Self-supported coils eliminate the need for a traditional bobbin or other support structure when the application allows. The coil is precision-wound on a custom mandrel using bondable magnet wire, with the winding bonded to maintain its geometry and mechanical integrity.
This construction can be particularly useful when space is limited or when the coil needs to be positioned close to surrounding metal components to maximize magnetic performance. Quality Coils can manufacture custom mandrels and winding arbors to achieve the required geometry and repeatability.
Encapsulated & Over Molded Coil Assemblies
Encapsulation and over molding can provide additional protection against moisture, chemicals, vibration, mechanical stress, and other environmental conditions.
Quality Coils supports several encapsulation processes, including upright transfer molding, injection molding, liquid pour, and varnish impregnation. The appropriate process and material depend on the electrical, thermal, mechanical, and environmental requirements of the assembly.
Custom Toroid Coil Assemblies
Toroid coils are wound around a ring-shaped core and are commonly selected when magnetic field containment, electrical efficiency, and compact packaging are important. Quality Coils manufactures custom toroidal coils for applications including aerospace, transportation, power supplies, audio, telecommunications, and other specialized equipment.
Toroidal coils can also be incorporated into custom assemblies when the finished component requires additional electrical connections, mechanical components, or other assembly operations.
The performance of an electromagnetic coil assembly depends on its electrical characteristics, magnetic design, physical construction, and operating environment. Since 1965, our team has helped customers develop and manufacture custom coil products and assemblies for unique applications. When developing a custom coil assembly, Quality Coils can evaluate requirements such as:
Electrical
Requirements
Mechanical
Requirements
Thermal and
Environmental Requirements
Determining these specifications early in the design process allows our engineers to evaluate manufacturability and help determine the appropriate coil construction and assembly approach. For quoting and design review, CAD files, engineering drawings, dimensional sketches, electrical specifications, or an existing component or sample can be especially useful.
Custom electromagnetic coil assemblies must meet both the electrical requirements of the application and the mechanical requirements of the finished product. Quality Coils maintains an ISO 9001:2015-certified quality system and has trained personnel supporting IPC-J-STD-001 with Space Addendum and IPC/WHMA-A-620 requirements.
Depending on the product and customer requirements, inspection and testing may include resistance, hipot, surge, dimensional, force, pull, and other application-specific tests. Our experts work with you to establish a custom coil assembly manufacturing process that delivers consistent performance and quality results you can depend on. Contact us today to review your custom assembly needs.
Quality Coils provides the engineering expertise and manufacturing capabilities to develop a complete solution for your application. We bring decades of experience to every project, and the commitment of a third-generation, US-based manufacturer to applications with unique requirements, mission-critical functions, and fast turnaround schedules.
A custom coil assembly is an electromagnetic coil that has been manufactured and integrated with additional electrical or mechanical components required for installation in a finished product. Depending on the application, this may include leads, terminals, connectors, housings, insulation, encapsulation, or other components.
Quality Coils manufactures and assembles several types of electromagnetic coils, including self-supported coils, tape wrapped coils, encapsulated and over molded coils, toroidal coils, and custom solenoid coils. The appropriate construction depends on the electrical, mechanical, environmental, and dimensional requirements of the application.
Yes. Quality Coils manufactures tape wrapped electromagnetic coils and can incorporate them into custom assemblies requiring specific electrical connections, leads, terminations, or other components. Tape wrapped construction can be appropriate for applications with relatively mild environmental conditions or for products where additional encapsulation will be performed as part of the customer's assembly process.
Yes. Quality Coils manufactures custom solenoid coils and can produce complete assemblies designed around the electrical and mechanical requirements of the application.
Yes. Quality Coils works with engineering and product development teams during the development process to help engineers evaluate manufacturability, coil construction, materials, dimensions, electrical requirements, and assembly considerations.
Yes. Quality Coils supports prototype development as well as production manufacturing, allowing customers to work with one coil manufacturer from initial design through final production.
The more information available, the more accurately the engineering and manufacturing requirements can be evaluated. Useful information may include:
If you do not have all of these specifications finalized, our team can review the information you have and help determine what is needed to move the project forward.
A custom coil assembly can simplify your supply chain, reduce internal assembly labor, and provide a more consistent finished component. With more than 60 years of experience in electromagnetic coil manufacturing, Quality Coils has the engineering knowledge and in-house capabilities to develop and manufacture assemblies for demanding OEM applications.
Whether you need a custom solenoid coil assembly, tape wrapped coil assembly, self-supported coil assembly, encapsulated coil, or another specialized electromagnetic assembly, we can help develop a solution around your requirements. Contact us today to discuss your project needs.
Quality Coils, Inc.
748 Middle Street | Bristol, CT 06010
Phone: 860.584.0927
Fax: 860.584.5954
