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Services | Coil Engineering

Induction coil design for a reliable induction process

The induction coil determines where the heat is generated, how fast the process proceeds, and how reproducible your result is. RF Heating Consult develops custom induction coils for soldering, hardening, annealing, shrinking, melting, and special induction processes.
Discuss your coil design
Combine with process testing
RF HEATING CONSULT

The Question

A good generator is not enough

In induction heating, the generator is the energy source, but the induction coil is the connection to the workpiece. An incorrect coil shape, excessive distance, poor cooling, or unfavorable product positioning quickly leads to uneven heating, long cycle times, or unstable quality.

That is why coil engineering at RF Heating Consult does not start with bending copper, but with the process: material, geometry, temperature, cycle time, available space, handling, and desired reproducibility.

Typical Questions

  • Which coil shape suits my product?
  • Is a round coil, hairpin, pancake coil, or multi-coil required?
  • How do I make the heating zone local and reproducible?
  • How do I prevent overheating of the coil, fixture, or product?
  • Can 3D copper printing enable a complex coil design?
The Question

Our Solution

From heat problem to
custom induction coil

Coil Design

We design induction coils based on product geometry, desired heating zone, frequency, power, and mechanical installation space.

Prototype and test

We verify thermal imaging, coupling, temperature curve, cooling, and reproducibility through laboratory and process testing.

Production Ready

We translate the prototype into a robust water-cooled coil with practical connections, fixture, and maintenance logic.
Our Solution

3D Copper Printing

Complex coils via 3D printed copper

For complex geometries, a conventionally bent copper tube may be insufficient. Therefore, we also include 3D copper printing of coils in the design process.

3D printed induction coils enable compact cooling channels, complex coil shapes, and highly specific heat profiles. This is particularly interesting in cases of limited installation space, short cycle times, hard-to-reach heat areas, or high demands on repeatability. Complex coil forms that are difficult to bend Integrated copper cooling channels Compact inductors for special product geometries Repeatable production of identical coils

  • Complex coil forms that are difficult to bend
  • Integrated copper cooling channels
  • Compact inductors for special product geometries
  • Repeatable production of identical coils
3D Copper Printing

Approach

Coil engineering in three steps

Just like with a good application approach, engineering begins with the application. This is followed by testing, dimensioning, building, and validation.
Custom induction melting coil engineering and design
1

Process analysis

We determine exactly what needs to be heated, which material is used, which temperature is required, and which process quality is required.
3D engineered helical induction coil for industrial heating
2

Concept and construction

We select coil form, water cooling, connections, concentrators, ceramics, and fixture. Where necessary, we evaluate 3D copper printing as an alternative.
Induction coil and pyrometer setup for temperature-controlled process validation
3

Testing and optimization

We validate the coil concept with real products and make adjustments regarding temperature distribution, cycle time, power, and reproducibility.
Approach
3D printed copper hairpin induction coil for precision heating

Applications

Induction coils for various processes

Inductive soldering

Coils for couplings, connectors, pipes, assemblies, and multiple solder positions. Induction Hardening Inductors for local hardening, scan hardening, rotating parts, and controlled hardening zones.

Inductive hardening

Inductors for local hardening, scan hardening, rotating parts, and controlled hardening zones.

Crimping and assembly

Robust coils for short cycle times, controlled temperature, and reproducible fit.

Flat heating

Pancake coils for plates, rings, dies, and local flat heat input.

Melting

Fuss coils, multi-winding induction coils, and coil concepts for crucible and material heating.

Special geometries

Custom inductors, including possible 3D printed copper coils for complex applications.
Applications

Practical application and design

Examples of coil engineering

The photos show examples of copper induction coils, HF connections, water cooling, busbars, and mechanical integration.
3D printed copper hairpin induction coil for precision heating

Hairpin coil

3D copper printed hairpin coil for complex geometry.
Custom induction melting coil engineering and design

Custom coil

3D design of an induction fuse with specific coupling.
Custom induction coils for industrial induction heating applications

Various coils

Overview of various custom induction coils.
3D engineered helical induction coil for industrial heating

Helix induction coil

Helix induction coil for directional cylindrical heating.
Multi-turn induction coil design for induction melting

Multi-winding fuse

Multi-winding fuse for efficient energy transfer.
Application and design examples

Contact

Do you need a custom induction coil?

Send us your workpiece, material, desired temperature, cycle time, available space, and any photos or drawings. We will then assess which coil concept fits best.

Discuss directly

No general contact form, but direct contact. That works faster for technical questions about coil engineering.
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