Quality Coils manufactures custom over molded coils and encapsulated coils that are designed to protect coil windings from moisture, chemicals, vibration, heat, mechanical stress, and other demanding conditions. Our engineering and manufacturing teams work with OEMs to select the appropriate encapsulation material and molding process based on the unique electrical, mechanical, dimensional, and environmental requirements of your application.
From prototype development through production, Quality Coils provides custom coil winding, encapsulation, over molding, electrical termination, inspection, and testing in-house. Our vertically integrated approach gives customers a single, experienced manufacturing partner from initial design through production – helping to streamline development, maintain quality and keep complex coil projects moving ahead efficiently. With more than 60 years of coil manufacturing experience, our encapsulated and over molded coil solutions are engineered for reliable performance and long service life, and we are ready to put our expertise to work on your project.
Molded coils are precision-wound electromagnetic coils that are enclosed in a protective material through an over molding or encapsulation process. The resulting construction helps protect the coil windings and electrical connections from environmental exposure while providing additional mechanical support and durability. Due to their construction, over molded and encapsulated coils are well suited for applications where dependable performance and long-term durability are essential.
Quality Coils manufacturers over molded and encapsulated coils for a wide range of equipment and industries, including:
We also manufacture encapsulated components such as connectors and diode packs when these components require additional environmental or mechanical protection. Because every application presents different electrical, mechanical and environmental requirements, our engineers are available to work with customers to determine the right coil construction, encapsulation material, molding process and tooling approach for the project.
Quality Coils offers multiple manufacturing methods to produce encapsulated and molded coils. Our team evaluates your system design, the electrical and environmental requirements, as well as your production needs and performance goals to determine an efficient manufacturing approach. This flexibility allows us to balance coil performance, durability, manufacturability and cost while delivering a solution for your unique needs.
Our over molded and encapsulated coil manufacturing capabilities include:
Transfer Molding
Encapsulating the coil within a molded protective material to provide mechanical and environmental protection. This process is well suited for applications requiring a robust, fully enclosed coil with consistent dimensions and repeatable production.
Injection Molding
Using injection molding equipment to produce repeatable molded coil configurations and integrated components, and often selected for applications with specific geometries, dimensional requirements, or higher production volumes.
Liquid Pour Encapsulation
Pouring liquid encapsulation materials around the coil to create a protective barrier around the winding and components, often used for complex coil geometries and applications requiring thorough environmental and electrical protection.
Varnish Impregnation
Applying varnish that penetrates and bonds the coil windings to provide electrical insulation and additional mechanical and environmental protection. It is well suited for applications that need improved winding stability without the added material of full molding or encapsulation.
Quality Coils provides custom tooling and engineering assistance to help develop the best approach to the manufacture of your molded coil design. Our integrated capabilities and diverse in-house production processes help customers optimize their electromagnetic coil manufacturing – providing efficiency, cost effectiveness and quality.
Contact us today about your needs and to discuss which molding or encapsulation process is right for your electromagnetic coil.
Material selection is an important part of molded coil manufacturing. The right encapsulation material can have a significant impact on a coil's electrical performance, durability and ability to withstand its operating environment. Quality Coils works with leading material suppliers to select encapsulation materials based on the electrical, thermal, mechanical, and environmental requirements. Depending on the application, encapsulation materials may be selected to provide specific characteristics such as:
Quality Coils has experience working with encapsulation materials from established suppliers, including DuPont, Phillips BMC, IDI, and Hysol. We bring six decades of custom electromagnetic coil manufacturing expertise to each project, leveraging our robust supply chain to efficiently source appropriate materials and maintain production continuity.
Since 1965, Quality Coils has provided industry-leading coil manufacturing capabilities - offering in-house winding, encapsulation, molding, electrical connection, inspection, and testing. Our integrated manufacturing approach allows us to support customers from prototype development through production while maintaining control over quality and process requirements.
Whether you are developing a new product or looking to improve an existing coil design, Quality Coils brings the experience that streamlines the path to production. As a leading over molded and encapsulated coil manufacturer for OEM applications, Quality Coils provides:
From the first prototype to full-scale production, Quality Coils combines engineering knowledge, manufacturing flexibility and hands-on expertise to help customers develop reliable solutions that are ready for the demands of the real world.
Encapsulated coils are used when a coil must operate reliably in environments where it may be exposed to moisture, chemicals, vibration, mechanical stress, temperature extremes, dust, or other contaminants. They are commonly used in industrial machinery, automation equipment, aerospace and defense systems, transportation equipment, refrigeration equipment, and other demanding applications.
The terms molded coils and encapsulated coils are often used interchangeably, although the specific manufacturing process can differ. Molded coils may use transfer or injection molding to form a protective material around the coil, while encapsulated coils may also use liquid pour or other encapsulation processes. The best approach depends on the application's environmental, electrical, mechanical, dimensional, and production requirements.
Encapsulation materials are selected based on the application's temperature, electrical, mechanical, chemical, and environmental requirements. Depending on the application and manufacturing process, materials may include thermoset compounds, thermoplastics, epoxies, silicones, and other protective materials.
Yes. Quality Coils manufactures custom molded and encapsulated coils based on customer electrical, mechanical, dimensional, and environmental requirements. Our team can also provide design assistance and support prototype development through production.
Yes. Our engineering team is available to review your design and develop initial prototypes for testing and proof-of-concept. We can advise on your design, evaluate expected coil performance, identify potential manufacturing considerations, and support the transition to full-volume manufacturing.
Yes. In addition to coils, we can encapsulate components such as connectors and diode packs when additional environmental or mechanical protection is required.
To develop an accurate quote, Quality Coils typically reviews the coil's electrical specifications, dimensions, operating environment, temperature requirements, encapsulation requirements, electrical connections, production quantities, and applicable specifications or standards. Drawings, CAD files, existing samples, or other technical documentation can also help our engineering team evaluate the application.
With more than six decades of experience in electromagnetic coil winding, Quality Coils manufactures encapsulated and over molded coils engineered for the unique requirements of your application. Whether your project presents challenging environmental conditions, requires complex tooling, or calls for specialized testing and certification, our team works alongside you to develop and manufacture reliable coil solutions.
Contact Quality Coils to discuss your over molded and encapsulated coil requirements and how our expertise can support your next project.
Quality Coils, Inc.
748 Middle Street | Bristol, CT 06010
Phone: 860.584.0927
Fax: 860.584.5954
