Bobbin Case Study

CREATIVE PROTOTYPING

Fast Turnaround Delivers Improved Product Solutions and Timeline

Project Profile

Our engineering team helped our client scale up and improved their product for a custom wound electromagnetic coil.

Challenge

1. The customer collaborated with Able Coil & Electronics after a failed effort with another supplier.
2. The product was costly, and didn’t meet their standards for the bobbin winding the application of the bobbin in use.
3. “The initial product was over-engineered and challenging to wind,” said Steven Rockefeller, President Able Coil & Electronics. “Using our 3D printing capabilities, we successfully suggested an alternative bobbin that was both simpler to print, and at a better value for the client without impacting product performance. Truly, a win-win.”

Schedule Consultation

Client Feedback

I’m a big fan of the multipart former – I think at this point any iterative changes are entirely at your discretion to optimize the job on your end as far as print time, material quantity, etc. From my perspective, this is a great product at a great price. I would love to revisit the possibility of a turnkey cube assembly in the near future. For reference, this is pretty much exactly what we pay to have these printed and wound by hand – if we can eliminate handwinding and its potential for error from the assembly process at little to no difference in assembly cost, I think it’s a slam dunk.

Thanks again for all the effort you’ve put into these, I can’t wait to see the new product in person.

Best, Blake

Project Explanation (Process)

Configuration Partners

In Able Coil & Electronics, our customer found a partner who could not only help to simplify the bobbin prototype, execute the complex winding and also print out the bobbin using a 3D printer to quickly evaluate the options.

Prototype Review

The original samples were submitted to Able Coil & Electronics for an initial prototype review.

Evaluation

Our Engineering team evaluated the samples, making creative suggestions to improve the bobbin prototype, tightened up the winding and created a slot for exiting the lead wires.

Printing

The first prototype was printed and machine wound by Able Coil & Electronics, and given to the customer to review. They were pleased with the samples, and asked Able Coil & Electronics proceeded with the product build.

Streamlined

Prior to the build, a further refinement to the bobbin prototype was suggested. Achieving the same technical results with a much less complicated 3D print, the Engineering team was able to reduce the print time, which subsequently meant the project cost stayed in line.

Outcome

The precision machine wound coil printed in house on Able Coil & Electronics 3D printer was delivered on time and within specification allowing the customer to meet their timeline and opened the door for future programs.