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Molded Coils

Services Offered

Molded coils are our specialty. Our multi-faceted molding capability includes eight transfer mold presses and four injection mold presses for both thermoplastics and thermoset materials. Epoxy transfer molding of coils and solenoids is the best protection against harsh environments. We also offer a poured molding process using liquid epoxies or silicone elastomers.

From mold design, to prototyping, to high-volume production, we assure high quality and close tolerances for virtually any application. Our molded coils are designed to meet or exceed customer expectations. Sag Harbor Industries employs UL approved class B, F and H insulation systems. We utilize large capacity shuttle presses up to 80 tons as well as multi-cavity molds for the lowest possible cost production of molded coils.

Production Capacities

  • A Variety of Molding compounds
    • RYNITE
    • RE5220
    • NYLON 6/6
    • SLAC EPOXY
    • RYTON
  •  
    • MH6-XXX
    • RTV 8112
    • EPOCAP 19284
    • EPON EPOXIES
    • INSULCAST EPOXIES
molded coils

Coil Terminations

Coil terminations are a critical path in connecting coils to the outside environment. We offer numerous solutions for terminating coils, below are just some of our capabilities:

  • Method
  • Dip or Hand Soldered
  • Ultrasonic and Fusion Welded
  • Potted or Overmolded
  • Type
  • Terminals, Tabs or Lugs
  • Self or Flexible Leads
  • PCB Connections
  •  
    • NPT or Conduit Connections
    • Welded tabs

Quality Assurances

We place a priority on quality. Our coils are produced in compliance with our ISO 9001:2008 certification. We maintain the absolute highest quality control measures to ensure customer satisfaction. Our self-auditing and inspection techniques are rigorous and thorough. Our team undergoes training and certification programs to ensure expert craftsmanship.

Our ISO 9001:2008 certification gives our customers the confidence that our production facilities, our internal and external auditing methods and our quality control procedures meet or exceed international standards. We consistently rank in our customer’s “Highest Vendor Ratings”. From product conception to application, our goal is to produce the highest quality product; as well as to deliver it on the designated date consistently and to continually improve in every aspect of our business.

Industries Served

  • Aerospace
  • Military and Naval Sensors
  • Automotive
  • Control Systems

Value Added Services

Value-added services are available per your requirements:

  • JIT/KanBan system options per customer's preference.
  • RoHS compliance at your request
  • 24-hour response time when responding to feedback
  • The products we make are completely proprietary and never compromised
  • Personal and direct service with on-site communication
  • Teamwork between us and you, with superior performance being the goal

Made in America

Sag Harbor Industries is a conscientious manufacturer. As a quality first company, the workmanship of our products is just as important as its price. The quality of American made products is second to none. Our customers can be assured that not only are Sag Harbor Industries products Assembled in America, they are also Made In USA, and we wear that distinction proudly.

That’s The Sag Harbor Advantage

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Details of Sag Harbor Molded Coils Capabilities
Molded Coil Catagories  
Field Coils, Self-Supported Coils, Solenoid Coils, Instrument Coils, Harsh Environement Coils, Air Coils
 
Terminations  
Soldered Lead Wires, Welded Lead Wires, DIN terminals, Tab Terminals, Crimped terminals, Stripped & tinned Magnet Wire
 
Wire Size   2AWG - 52AWG
 
Wire Materials   Copper, Brass, Aluminum, Copper Clad Aluminum, Copper Nichol Alloys, Copper Tin Alloys, Silver, Gold, Stainless Steel
 
Wire Insulation Materials   Polyurethane, Polyester, Polyesterimide, Polyimide and combinations of these
 
Coil Temperature Ratings   105⁰C - 240C⁰
 
Bobbin Materials   Nylon 6/6, Glass filled nylon 6/6, Glass Filled PBT, Glass Filled PET(Rynite), Glass Filled PPS (Ryton), Liquid Crystal Polymer, Thermosetting Polymer, Phenolic, Glass filled DAP
 
Molding  Processes   Over-Molded, Transfer molded, Injection Molded, Poured Epoxy
 
Molding Materials   Rynite®(PET), Ryton®, Zytel® (nylon), Farboset
 
U.L. Insulation Systems   Class B,F, H
 
Yokes and frames   C and D Frames along with Custom Yokes