Air Coil Winding
Air coil winding is a precision manufacturing process that shapes bare wire into self-supporting electromagnetic coils without a magnetic core. Unlike bobbin-wound coils, air coils rely solely on the wire’s own geometry to maintain their shape, making them ideal for high-frequency applications where core losses and saturation must be eliminated.
At Mach Prototype, we manufacture custom air coils to your exact specifications — from single prototype runs to low-volume production. Our winding process delivers consistent dimensional accuracy, tight pitch control, and reliable electrical performance across every batch.
Winding Types and Material
Flat Wire (Rectangular) | Round Wire | |
Rectangular Coils | High copper fill factor, low DC resistance, excellent heat dissipation. Ideal for high-current planar assemblies. | Versatile and cost-effective, easy to terminate, wide gauge range. The standard choice for general-purpose PCB-mount coils. |
Typical: EV onboard chargers, DC-DC converters, power inductors | Typical: RFID antennas, proximity sensors, general inductors | |
Triangle Coils | High current density in a compact angular footprint; specialized field distribution for space-constrained power modules. | Flexible angular profiles for non-standard layouts; lightweight and easy to form into custom geometries. |
Typical: Compact power modules, high-density sensor arrays | Typical: Space-constrained sensors, custom antennas, precision detection coils | |
Linked Coils | Multi-section interconnected arrays with high current handling; complex field shaping with minimal parasitic loss. | Interconnected or multi-coil arrays with flexible routing; easy to customize section count and spacing. |
Typical: Multi-phase power systems, industrial induction heating, complex field generators | Typical: Multi-channel sensor arrays, RFID matrix antennas, gradient field coils |