Custom Wound Electric Coils

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At Endicott Coil Company, Inc., we have an expert engineering staff that specializes in custom electric coil winding assemblies. Our experience and versatility allow us to design and build any variety of coil type including air core, injection molded, impregnated, bobbin wound, and sensing coils. Our coils are built using 48 to 10 AWG sized wire in single layer, multi-layer, wet wound, dry wound, random layer, or precision winding configurations, depending on the application. Thermal Class insulations from 105°C – 240°C can be used and bobbins can be fabricated from Zytel, glass-filled nylon, Rynite, Ryton, LCP, Delrin, PEK or other custom materials as needed.

We use CNC winding equipment to ensure precision windings with tolerances as tight as .002″. All of our custom coil winding assemblies are subjected to applicable hipot, resistance, inductance, leak, and surge testing to ensure our customers’ specifications are met. Our tooling and machining is done in-house. We have experience serving the aerospace, nuclear, automotive, medical, and computer industries and meet all applicable UL, CSA, VDE, Mil-Spec, and NRC standards. Our commitment to innovation and quality has allowed us to meet and exceed our customers’ expectations for over 50 years. For more information about our custom electric wound coiling capabilities, please see the table below, or contact us directly.

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Details of Endicott Coil's Custom Coil Winding Capabilities

Coil Types

Self-Supported (Air Core)
Transfer and Injection Molded
Impregnated
Bobbin Wound
Solenoids

Stator
Brake and Clutch
Buzzers and Vibrators
Sensing

Coil Winding Process

Single Layer
Multi-Layer
Wet Wound

Dry Wound
Random Layer
Precision Winding

Wire Material

Copper

Wire Shape

Round
Square
Rectangular

Insulation Material

Thermal Class

Bobbin Materials

Zytel
Glass Filled Nylon
Rynite
Ryton

Liquid Crystal Polymer (LCP)
Delrin
PEK
Other Materials

Wire Size

48 to 10 AWG

Temperature Range

105 to 240 °C

Coil Shapes

Triangular
Square
Round

Trapezoidal
Pie / Wedge
Custom

Coil Winding Maximum Diameter

14 in

Winding Tolerance (+/-)

.002 in

Added Value Processes for Coil Finishing

Coil Potting/Encapsulation (Rubber or Epoxy)
Thermally-conductive Epoxies
Water Cool Plates
Stripping

Tinning
End Connector Assembly
Electrical Testing

Coil Winding Equipment

Computer Controlled
Spot Welding
Automatic Termination

Testing Equipment

Gauss Meters
Ohm Meters

High Pot Testers
Leak Testes

Testing Capabilities

High Pot Testing
Inductance Testing
Resistance Testing

Leak Testing
Surge Testing

Inspection

Line

Secondary Services

Design and Engineering
In-House Tooling and Machining
Transfer Molding
Injection Molding

Vacuum Impregnation
Encapsulating
Ultrasonic Welding
Assembly

Production Volume

1 to 100,000 units
Prototype

Short Run
Large Scale Production Runs

Additional Information

Industry Focus

Transportation
Power Transmission
Automotive
Metering

Medical
Nuclear Energy
Aircraft / Aviation
Computer

Intended Applications

Aerospace Applications
Automatic Fire Door Closers
Automatic Switches
Circuit Breaker Coils & Solenoids
Current Transformers
Dental Valves
Electric Brakes & Clutches for Construction Equipment
Electronic Locks
Elevator Solenoids & Relays
Fuel Monitors
Fuel Sensors
GPS Sensors
Ground Fault Interrupters
Hand-held Scanner Components
Lighting for Hazardous Areas
Linear Vibrators

Marine Applications
Measuring Equipment
Metering Applications
Microwave Amplifiers
Medical Valves
Position Sensors
Power Transformers
Power Transmission
Printer Components
Precision Instruments
Recreational Vehicles
Security Systems
Sensing Transformers
Tattoo Equipment
Technical Cameras
Time and Productivity Recording

Quality

ISO Methodologies
SPC Techniques
Case Studies

Process Capability Indices
On-Going Improvement

Industry Standards

UL
CSA
VDE

RoHS
Mil-Spec
Nuclear Regulatory Commission (NRC)

File Formats

AutoCAD
MathCAD

Have Any Questions?Get In Touch Today!

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