Coils

We pride ourselves on having the ability to produce custom coils to our customers' exacting orders. Our wide assortment of automated coil winding machines produce coils with precision, efficiently and economically.

Custom coils are specially engineered coils that are shaped and designed to perform unique functions for a variety of operations. Sag Harbor Industries has the skills and expertise to take any conceptualization and make it a practical reality. Regardless of how complex the design or how innovative the function, we have the tools and experience to meet your needs.

What is Custom Coil Design?

While standard coil designs suit many applications, some processes demand unique adjustments to accommodate unconventional requirements. These specialized applications call for expert coil design knowledge to create solutions that seamlessly integrate into new systems. This is where custom coil design by Sag Harbor Industries excels.

At Sag Harbor Industries, custom coil design starts with understanding the specific frequency of the required current and the coil’s intended function. Our engineers collaborate closely with clients, providing clear consultations to define the necessary specifications. This ensures the coil fits efficiently into your schematic, delivering reliable performance tailored to your needs. Types of Coils and Their Applications

What are the Different Types of Coils?

There are an endless number of types and kinds of coils since they are a necessary part of so many devices. Each variety of coil begins with some form of wire winding, which needs to be adjusted to fit the final application and the requirements of the coil’s design.

Electric coils are found in electric motors, generators, inductors, and electromagnets. They serve as a conductor of electricity to efficiently send electrical current to power motors. Electric coils are tightly wound and are engineered for consistent and reliable performance.

Encapsulated coils are similar to solenoid coils with the exception that they are coated with resin, which protects the wires of the coil from moisture and damage. The extra protection provided to encapsulated coils gives them extra strength and longevity. As with all other coils, encapsulated coils can be engineered to fit the needs of any industry.

Field coils are designed to generate electrical current for a variety of applications. They come in standard designs but can be produced for specific customer applications. Some of the various types of field coils include encapsulated, glass taped, tape wrapped, injection molded, transfer molded, and loose or bobbin wound as well as self-supported. Self-supported, or air coils, are used as a solution for uncommon and irregular applications, where space is a concern. Since self-supporting coils are bobbin-less, they are wound using magnetic wire that is added during the manufacturing process.

Solenoid coils, another of the common coils, is a foundational element for a variety of applications. Though solenoid coils are generally used, there are functions where they require special designing and need custom winding, a specialty of Sag Harbor Industries.

Coil Protection

As an added value, custom coils can be coated to protect them from harsh and demanding conditions. There are a variety of materials that can be applied to coils that increase their life span and offer protection from the elements. Protective materials include thermoplastics, thermoset, and varnish.

Molded coils are produced using transfer or injection mold presses. Thermoplastics and thermosets are applied, which include RYNITE, RE5220, MH6-XXX, RTV8112, and several other long-lasting protective materials. The choice of material depends on the application and environment that the coil will have to endure. Sag Harbor Industries offers UL rated Class, B, F and H approved systems. We Transfer and Injection mold, Liquid pour and vacuum impregnate our coils. The materials we use are based on your application and its environment.

An alternative molding process for the application of coatings is pour molding, where liquid epoxy or silicone elastomer is poured over the coil. Pour molding is another specialized service offered by Sag Harbor Industries to meet customer needs.

Varnishes are applied to coils dipped brushing, spraying, or vacuum impregnation and baking. The type of coil can be bobbin or bobbin-less with bobbin-less coils ranging in sizes from 2AWG to 50AWG. The benefits of varnishing a coil include protection from harsh environments, corrosion, and any form of mechanical damage.

Whatever your coil needs, Sag Harbor Industries has the technology, expertise, and experience to develop a custom designed highly reliable coil that will perfectly fit your requirements.

Precision Engineered Coils for Specialized Electrical and Electromechanical Applications

Sag Harbor Industries designs and manufactures custom coils engineered for demanding electrical, magnetic, and electromechanical applications. Our automated coil winding systems support consistent tension control, uniform layering, and repeatable performance across a wide range of coil geometries. Each coil is configured to meet specific electrical, thermal, and mechanical requirements, ensuring reliable operation in motors, solenoids, sensors, actuators, transformers, and custom assemblies.

Comprehensive Coil Manufacturing Capabilities

Our engineering team develops coil solutions that integrate seamlessly into customer schematics and equipment designs. We support complex winding patterns, multi layer constructions, bobbin based and bobbin less configurations, and specialty shapes for unique applications. Whether the requirement involves high frequency performance, magnetic field generation, compact form factors, or rugged environmental conditions, Sag Harbor Industries provides tailored coil designs backed by decades of manufacturing experience.

Coil Types and Application Specific Configurations

We produce a full range of coil types, including electric coils, encapsulated coils, field coils, molded coils, self supported coils, solenoid coils, and varnished coils.

• Electric coils support motors, generators, inductors, and electromagnets requiring consistent electrical conduction and stable magnetic performance.
• Encapsulated coils use resin coatings to protect windings from moisture, vibration, and mechanical stress.
• Field coils are available in glass taped, tape wrapped, molded, and self supported formats for current generation and magnetic field control.
• Self supported coils provide solutions for irregular geometries or space restricted applications.
• Solenoid coils are wound for actuation, control systems, and precision motion applications.
• Varnished coils receive protective coatings through dipping, spraying, or vacuum impregnation to enhance durability.

Protective Coatings and Molding Options

Coils can be protected using thermoplastics, thermosets, varnishes, and specialized encapsulation materials. Injection molding, transfer molding, liquid pour, and vacuum impregnation processes are available to match environmental and performance requirements. Materials include RYNITE, RE5220, MH6 XXX, RTV8112, and other long lasting compounds. UL Class B, F, and H systems are available for applications requiring elevated thermal performance.

Engineering Support and Custom Development

Custom coil design begins with defining electrical frequency, operating conditions, and functional requirements. Our engineers collaborate closely with customers to determine winding specifications, wire gauges, insulation systems, and protective materials. This ensures each coil integrates cleanly into the final assembly and performs consistently under load.

FAQs

What Types of Custom Coils Do You Manufacture?

We produce electric, encapsulated, field, molded, self supported, solenoid, and varnished coils for a wide range of applications.

Can Coils Be Designed for Unique or Irregular Geometries?

Yes, self supported and custom wound coils can be engineered for uncommon shapes, tight spaces, or bobbin less configurations.

What Protective Materials Are Available?

Options include thermoplastics, thermosets, varnishes, epoxy coatings, silicone elastomers, and molded encapsulation systems.

Do You Provide Engineering Support for Custom Coil Design?

Yes, our engineers collaborate with customers to define electrical, mechanical, and environmental requirements for fully customized coil solutions.

Why Choose Sag Harbor Industries?

With advanced technology, deep expertise, and years of experience, Sag Harbor Industries delivers custom-designed coils that meet your exact requirements. Whether you need electric coils, solenoid coils, or protective coatings, we ensure high reliability and performance in every product. Contact us today Toll Free:1-800-724-5952 to discuss your custom coil needs and discover how we can support your next project!

That’s The Sag Harbor Advantage