Finished coils straight off the winder, with no post-forming, better consistency, and higher yield for our customers
Wiresun a contract manufacturer of precision motor coils, has upgraded its coreless (hollow-cup) coil production line with a new one-step winding process. Coils now come off the machine as finished cup-shaped coils, with no secondary forming required. Customers get more consistent coils, lower defect rates, and shorter lead times.
Why Traditional Coreless Coils Fall Short?
In conventional coreless coil production, coils must be pressed, rolled, and corrected after winding. Each extra step adds risk:
Pressing can damage the enamel insulation, causing shorts or broken wires.
Repeated clamping introduces dimensional variation from coil to coil.
More process steps mean more labor, longer cycle times, and higher cost.
For motor makers, these issues show up as inconsistent motor performance and lower assembly yield.
Our Process: Wound and Cured in One Step
Our production line now uses multi-axis 3D synchronized winding. Self-bonding wire is cured with hot air during winding, so each coil takes its final shape as it is wound. No pressing, rolling, or correction is needed afterward.
What This Means for Our Customers?
Tighter tolerances: No secondary clamping, so dimensional deviation stays minimal.
Reliable insulation: No pressing means no enamel damage and fewer broken-wire defects.
Low internal stress: Coils hold their shape and perform consistently.
Batch-to-batch consistency: A stable fill factor across every production run.
Shorter lead times: A simpler process flow speeds up delivery.
Competitive pricing: Lower labor costs and higher yield help keep your costs down.
Applications
Our coreless coils are suited for humanoid robot joint motors, medical devices, drones, and precision servo motors, where size, weight, and consistency are critical.
Custom Coil Manufacturing
We wind coils to your specifications, including wire gauge, turns, dimensions, and resistance. We support everything from prototypes and small batches to volume production. [CE/ISO/ROHS]
Get a Quote
Send us your drawings or specifications, and our engineering team will respond within 24 hours.
About WIRESUN
Founded by a management team with over 30 years of hands-on expertise in coil winding, WIRESUN has grown into one of Dongguan's trusted precision coil manufacturers. We provide OEM and ODM custom coil winding services, producing air core coils, bobbin coils, and special-shaped coils, along with coil winding machines and wire tensioners.
Contact us:
sales@wiresun.com ｜ +86-186 2185 7689 (Bi Danfeng)