All About Micro-Coils: Characteristics, Manufacturing, and Applications

November 17, 2022

The micro-coils or electromagnetic coils are very tiny devices where an electric current interacts with a magnetic field. Due to the tiny size of the micro-coils, they have significant uses in the preparation of multiple medical devices. The core process of manufacturing the micro-coils is the coil winding process that involves the twisting of an electrically conductive wire. Generally, micro-coils can have different shapes, such as a spiral, helix, or coil. However, a specific application area can have a great influence on the shape and dimensions of these coils. Based on the application area, the desired level of magnetic field strength, resistance, and inductance changes, and therefore, the shape and size of the coils also change. For the manufacturing of tiny micro-coils, manufacturers will need a microscope or magnifying glass. 

As micro-coils help to generate collaboration between an electric current and a magnetic field, these coils are crucial elements of various devices, such as electromagnets, inductors, transformers, and sensors. To produce the interaction, micro-coils either engender a magnetic field by providing the flow of an electric current or engender an electric current by providing an external magnetic field.

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The Size Constraints of the Micro-Coils

For the preparation of a wide range of medical invasive devices, micro-coils are essential. As the size of these devices is very tiny, the main challenge for the manufacturers is to fit the coils into these devices. Conversely, to deal with the increasing demand for transducers and sensors, manufacturers are producing very tiny micro-coils. 

Manufacturing Challenges

The manufacturing process of micro-coils requires micro-motion controlling and positioning systems. Eight to nine microns ultra-fine wires are ideal for the preparation of micro-coils. The most difficult part of the manufacturing process is to work with these tiny wires, and this requires custom-made equipment and methods.

The Connectivity Solution

During the development process, manufacturers have to develop a connection between two ultra-fine wires. When it comes to providing connectivity solutions between ultra-fine wires, no traditional method is suitable. Modern manufacturers have found thermal compression bonding technology to be the most efficient method for connectivity solutions. Whether the wires are similar or different in diameters, this method is extremely reliable and durable. This method also eliminates the possibility of strain and corrosion at the joints. 

The Micro-Coil Winding Method

A major part of the manufacturing process is the coil winding process which involves the twisting or turning of ultra-fine wires around a core or pin by using custom-made equipment. During this process, manufacturers focus on maintaining the strict tolerance requirements as well as the standard of the coils.


Electromagnetic micro-coils have various applications in different fields. For the preparation of orientation and navigation sensors, micro-coils have a critical role, and these sensors are useful in different operations such as endoscopic manipulation, targeted radiation catheters, targeted drug delivery, stent positioning, implanted markers, and highly accurate ablations. Micro-coils are also necessary for the manufacturing of active implants, such as pacemakers and pain management devices. Other crucial applications of these coils are diagnostics, therapeutic applications, dental and orthopedic treatments, etc.

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