Self- Supported Coils

Quality Coils, Inc. manufactures self-supported electric coils for applications where performance, space constraints, and magnetic efficiency leave no room for compromise. By eliminating the bobbin when the design allows, our team is able to position the electromagnetic coil winding as close as possible to surrounding metal components - maximizing magnetic strength while maintaining mechanical stability.

This approach is ideal for compact or high-performance assemblies where traditional coil constructions introduce unnecessary limitations. Our engineers evaluate each application to determine when a self-supported configuration delivers measurable gains in efficiency, durability, and overall system performance.

At Quality Coils, self-supported electric coils are precision-wound on custom mandrels using bonded magnet wire selected specifically for the electrical, thermal, and mechanical demands of the application. Our team selects the coil wire’s bond method based on performance requirements as well as the application specification, with options including controlled oven curing, resistive (electrical) heating, induction heating, or solvents.

What sets Quality Coils apart is not just the winding process, it’s our ability to design and produce the right mandrel or winding arbor to achieve consistent geometry and repeatable results. Each self-supported coil we product meets tight tolerances while maintaining long-term structural integrity in real-world operating conditions.

Self-supported coil winding can offer a variety of advantages, especially in application where performance and packaging size must be optimized. These types of electric coils often:

Are compact without sacrificing magnetic output
Improvs magnetic efficiency by reducing distance to adjacent metal components
Reduce potential failure points by eliminating unnecessary mechanical elements
Provide greater design flexibility for custom electrical and dimensional requirements

Our experienced team combines engineering expertise with a deep understand of coil performance in real-world applications, allowing Quality Coils’ solutions to perform reliably over time, even under tight space or thermal constraints, and in the most demanding environments.

Our experience across diverse industries allows us to tailor a self-supported coil’s design to its operating environment - ensuring the right balance of magnetic performance, durability, and manufacturability.

While we produce a variety of electric coil types – including encapsulated and over molded coils, tape wrapped electromagnetic coils, and toroid coils - our self-supported electric coils are often used for:

Motion & Actuation – such as voice coils, solenoids and actuators
Sensors & Measurement – including position and displacement sensors, and magnetic field sensors
RF & Communications – especially in low-loss or high-frequency applications.
Medical & Life Science Equipment – including imaging, diagnostic, implantable electronics and wearable devices.
Automotive & Aerospace – across systems with fuel injectors, valve actuators, sensors, and controls
Industrial & Power – such as relays, contactors, specialty transformers and inductive components.

We also manufacture a wide range of custom coil assemblies to meet unique needs.

What types of wire materials are used in the manufacturing of self-supported coils?

While materials are specified based on customer requirements or based on our recommendations to support optimal performance, commonly we use an enameled copper wire that is coated with a thermoplastic adhesive layer. We also use copper-clad aluminum wire and high frequency litz wire for many projects, and can also utilize unique material types based on the application requirements.

What information do you need to quote the cost to manufacturer a custom self-supported coil?

To help quote costs accurately, detailed information about the electrical, spatial, and environmental requirements are needed, such as:

CAD drawing or dimensional sketch
Wire diameter, wire length and lead wire positions
Electrical specifications including the required inductance, maximum resistance, operated current (nominal and peak), maximum voltage and operating frequency range
Finish or encapsulation requirements
Maximum and minimum operating temperatures
Unique environmental conditions defining a self-supported coil’s potential exposure to moisture, dirt/dust, electrical fields, chemicals, pressures and more
Mounting requirements
Certification requirements
Order details including quantities and delivery requirements

JOIN OUR TEAM