Ultra-Fine Wire Winding from φ0.016mm | Contract Manufacturing of Micro Coils for Medical and Precision Equipment

PRONEC CO., LTD. provides contract manufacturing for Micro Coils using ultra-fine wires starting from 0.016 mm in Thailand. We meet the demands for high-precision coil winding for medical devices and high-precision machinery, ranging from prototyping to mass production, utilizing our self-developed winding machines and precision control technology.

Table of Contents

• Integrated Production in Thailand: From Prototype to Mass Production
• Ultra-fine Winding Technology at 0.016 mm
• Quality Management System for Medical Devices
• Design Support with Self-Developed Machinery
• Frequently Asked Questions (FAQ)

Integrated Production in Thailand: From Prototype to Mass Production

When considering the procurement of precision coils in Thailand, it is common to split the work keeping prototyping in Japan and mass production in Thailand. This often leads to increased logistics costs and longer lead times. PRONEC CO., LTD. operates self-developed winding machines and peripheral equipment within our Thai production base, enabling a fully integrated service in one location, from prototype development to mass production of hundreds of thousands to millions of pieces per month.

Our Japanese management team coordinates with Thai engineers who possess deep technical expertise to ensure production meets rigorous quality standards, reducing the risks associated with local sourcing. Additionally, we support in-house processes such as molding, winding, assembly, and resin overmolding. This minimizes quality fluctuations and delivery delays that might occur when moving products between different facilities during the process.

Ultra-fine Winding Technology at 0.016 mm

Coils used in medical solenoid valves or miniature sensors require high-density winding to achieve the maximum number of turns in limited space. This is especially critical when using ultra-fine wires smaller than 0.04 mm, as even slight fluctuations in tension can lead to wire breakage, coil deformation, or inconsistent electrical characteristics.

Our company utilizes Servo Tension and Electronic Tension systems to measure and provide real-time feedback on the load applied to the winding motor, allowing for maximum tension precision. As a result, even with ultra-fine wires starting from 0.016 mm, we consistently deliver beautiful, high-density aligned winding. To address wire breakage during soldering, a common issue with fine wires, we also improve production yields by proposing manufacturing methods such as twisting (stranding) the wire ends.

Quality Management System for Medical Devices

Medical device components that impact human lives such as solenoid valves in dialysis machines or coils for high-reliability precision machinery require rigorous inspection systems and data support. Hand-written inspection logs carry the risk of errors or illegibility, which can hinder rapid root-cause analysis if problems arise.

To solve this, we have implemented QC Pro automated measurement software. We have built a system that automatically records, calculates, and analyzes measurement data to eliminate human error and deliver highly accurate inspection reports. This allows us to maintain detailed traceability for every production lot, meeting the strict quality requirements of the medical, automotive, and precision machinery industries.

Design Support with Self-Developed Machinery

Challenges in the development phase such as "standard winding machines cannot perform the task" or "dimensions do not match the design" can take months to resolve if relying on external machine manufacturers for customizations. PRONEC designs and develops its own winding machines, allowing us to quickly produce specialized jigs or machinery tailored to unique shapes or product specifications.

We operate as a development partner, engaging from the customer's design or conceptual stage and evaluating manufacturability through winding simulations. For example, we can verify the limits of high-density aligned winding for cylindrical air core coils. Providing technical evidence-based proposals helps reduce the number of design revisions and shortens the time to market for new products.

Frequently Asked Questions (FAQ)

Q: Can we consult with you if we don't have a complete drawing yet?
A: Yes. We are ready to support you from the conceptual and simulation stages to find the most suitable manufacturing method before actual production begins. We focus on problem-solving and designs that are optimized for real-world manufacturing.

Q: Do you accept prototype orders for just a few pieces?
A: Yes, we do. We are happy to produce prototypes or small sample quantities while establishing the parameters required for future mass production.

Q: Is the quality standard of the Thai factory equivalent to Japan?
A: Yes, it is equivalent. While the technical expertise is held by our Thai engineers, our Japanese team who deeply understand factory operations coordinates the process. We use the QC Pro system for 100% data recording and maintain strict traceability.

※ For more details, please download the attached documentation or fill out the inquiry form below.