Individually manufactured components such as coils, transformers or chokes, machine-made or handmade by our specialist staff.
At TPS Elektronik, we design and manufacture custom electromagnetic coils, coils and transformers, and complete motor assembly / motor asm sub-assemblies for electronics, power conversion, motion control, and sensing. From micro bobbins to heavy chokes, our coil winding services combine engineering, materials selection, automated winding, impregnation, overmoulding, and final electric assembly—all under one roof.
What We Build
Transformers
- Power, signal, and high frequency transformer / high frequency transformers (flyback, forward, LLC).
- Copper or aluminum windings (we support both as an aluminum winding transformer manufacturer and copper winding transformer manufacturer).
- Planar and toroidal coil winding / toroidal coil winder options; interleaved windings for low leakage.
Inductors & Chokes
- Buck/boost inductors, PFC chokes, common-mode chokes, and dv dt choke for VFD/inverter outputs.
- Ribbon wound coil winding services (flat wire) for high current and low loss.
- Pancake coil winding services (spiral/planar) and oscillate coil winding services (oscillating layer patterns) for thermal and space optimization.
Solenoids & Electromagnets
- Valves, locks, actuators: solenoid coil winding, matched solenoid coil pair windings / solenoid coil pair winding packs for push-pull.
- Custom electromagnetic coil and custom electromagnetic coil assemblies (iron/steel pole pieces, plungers).
- Helmholtz coils for magnetic field uniformity and coaxial coil geometries for specialized fields.
Motors
- Induction motor coil winding (stators/rotors) and small DC/BLDC stators.
- Repair/rewind and new builds with varnish or VPI, plus full motor winding services / motor winding service.
Other Specialty Coils
- Magnet coil / magneto coil winding services (ignition).
- Miniature coil winding service for sensors, relays, and micro-actuators.
- Coil kits, bobbins, and bonding wire/leadouts pre-tinned for PCB or terminal blocks.
Materials, Wire & Insulation
- Conductors: oxygen-free copper wire coil or aluminum; round, ribbon wound (rectangular) and Litz.
- Insulation systems: enamelled copper insulation wire / insulating wire, sleeves, tapes, wire coating and impregnation varnishes.
- Wire insulation design to insulate wires per creepage/clearance and target isolation class.
- We source magnet wire from audited transformer winding wire manufacturers.
- Note: while familiar with resistance alloys (vape coil wire as a category), we do not build consumer vape coils.
Process & Coil Winding Technology
Equipment & Automation
- Programmable electric coil winding machine / electric coil winder with tension and traverse control.
- Toroidal coil winding machine cells for distributed-gap cores; toroidal transformer winding machine manufacture partners for capacity upgrades.
- Solenoid coil winding machine / solenoid coil winder for long, tight layers.
- Induction motor coil winding machines / stator winder manufacturer / stator coil winding machine manufacturer integration for large runs.
- Inline soldering, crimping, taping, sleeving, overmoulding and potting; automated test and serialization.
- We collaborate with top transformer winding machine manufacturers / transformer winding machine manufacturer, transformer coil winding machine manufacturers, stator winding machine manufacturers, and broader coil winding equipment manufacturers.
Lines & Flow
- Automated production lines for winding and QA checkpoints; armature winding production line options for DC motors.
- Documented transformer winding manufacturing process from core prep to final test.
Finishing & Assembly
- Varnish dip or VPI; thermoset/UV potting; custom housings.
- Harnessing and terminals; PCB pinning; connectorization; final electric assembly.
Quality & Testing
- Electrical: DCR, inductance/Q over frequency, turn/phase polarity, hipot/insulation resistance, surge (where applicable).
- Thermal: rise tests and hot-spot checks for high frequency transformers.
- Mechanical: pull-force on terminations; visual per IPC-620.
- Traceability: lot/batch recording and stored test reports.
Engineering & DFM Support
- Core selection (ferrite, powdered iron, nanocrystalline), window utilization, thermal paths.
- Layering, foil vs round, interleaving, shielding (electrostatic screens).
- Custom transformer winding design, creepage/clearance tables, and safety standards guidance.
- Rapid prototypes via our coil winding service / custom coil winding services / special coil winding services, scaling to volume.
How-To Corner: Solenoids (Quick Answers)
How to wind a solenoid coil / how to wind a coil solenoid / how do I wind a solenoid coil?
- Pick wire gauge for resistance/current.
- Choose bobbin and stroke
- Wind layers with even tension and layer paper as needed
- Tie-offs with bonding wire or soldered leads
- Impregnate or pot for stability.
Determine the direction of winding in a solenoid coil
Use the right-hand rule: curl your right-hand fingers in the winding direction; your thumb points to the magnetic north of the solenoid coil. For solenoid coil pair windings, wind the pair so fields add for pull or oppose for differential sensing.
Equipment & Partners (for buyers searching equipment as well as services)
While we are a custom coil winding service manufacturer, some visitors search for equipment such as electric motor coil winding machine, toroidal coil winder, or “transformer winding machine manufacture / manufacturer.” We partner with reputable transformer coil winding manufacture and coil winding equipment manufacturers to ensure capacity and repeatability—so whether you need wire winding service or guidance on machinery, we can help.
Typical Applications
- Power conversion: PFC, DC/DC, AC/DC, induction coil winding for heating.
- Motion: motor winding services for pumps, fans, compressors.
- Sensing & test: Helmholtz coils, probes, coaxial coil assemblies.
- Transportation & industry: drives, welders, chargers.
- Medical & lab: field coils, gradient sub-assemblies.
FAQs
What is motor winding service?
It’s the engineering, winding, insulation, impregnation, and testing of stator/rotor windings for new motors or repairs—often including varnish/VPI and balancing.
Types of motor and generator winding services?
New build, rewind/repair, slot liner replacement, coil insertion/forming, VPI, surge/hipot testing, and end-turn bracing.
Motor winding service near me / motor winding services near me
We serve global OEMs. If you searched these phrases, we can support you via regional logistics and service-level agreements.
Do you make bobbins and “bobine self”?
Yes—bobbins and inductor (“bobine self”) assemblies with standard or custom formers.
Do you support toroidal and planar transformers?
Yes—toroidal coil winding and planar/foil designs, plus custom transformer winding.