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PRONEC CO., LTD.
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Pushing the Limits of Layer Winding! A Case Study of Air-Core Coil Verification Using In-House Winding Machines
2026-05-05
In manufacturing, a wide variety of coil shapes are required to meet specific space and performance requirements. Among these, cylindrical air-core coils are particularly difficult to wind due to their geometry, and the precision of the layer winding significantly dictates the final product's quality.
This report presents an independent verification case study initiated by a customer inquiry: "To what extent is perfect layer winding achievable on a cylindrical coil with a 20.5mm winding width?" The motivation behind this challenge was also driven by our engineers' desire to personally test the absolute performance limits of Proneck winding machines.
Coil Specifications for Verification
Shape: Cylindrical air-core coil
Wire Diameter: φ0.08 mm (Ultra-fine wire)
Inner Diameter: φ2 mm
Width (Winding Width): 20.5 mm (Maximum capacity of our winding machine)
Challenge and Results at 3,000 rpm
To simulate actual mass-production conditions, the winding was performed at a rotational speed of 3,000 rpm. The results confirmed that a perfectly aligned cylindrical layer winding is achievable for up to 8,000 turns.
Note: The white line-like markings on the 8,000-turn coil are fragments of the self-bonding film caused by the routing of the lead wires.
Summary: Solving Prototyping and Mass Production Challenges with High-Precision Winding
At Pronec, we utilize our in-house winding machines to solve customer challenges across a wide range of needs, including air-core and bobbin coils.
You want to prototype specifications that other companies were unable to wind.
You want to achieve high-density, perfectly aligned layer winding
You want to ensure long-term stability in your winding process.
If you are facing any of these challenges, please feel free to consult with us. With a system that provides end-to-end support from prototyping to mass production, Pronec engineers will handle your request directly.
▶ For consultations and quotes, please use our Web Inquiry Form.
We look forward to hearing from you.
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Industry Classification
Medical equipment / Electrical component for transportation equipment / Electronic parts
Main 3 Products
Air core coil, Bobbin coil, Coil Assembly, Solenoid coil, Wireless power transfer coil, WPC, RFID, Winding machine, OEM / Plastic molded products, overmolded products
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PRONEC is a specialized manufacturer in Thailand with over 30 years of experience in air-core coils, precision coils, and electronic component assemblies. With integrated in-house capabilities from pr ...
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