Custom Coil Winding | Custom Coil Bending
Custom Coil Winding

Custom Coil Winding from HBR Industries,Inc.

Custom Coil Bending

Custom Coil Bending from HBR Industries,Inc.

Wire Gauge Chart ( AWG Gauge) Diameter in Inches and MM)

Custom Wire Winding, Custom Wire Coiling & American Wire Gauge

At HBR Industries, Inc. we can create custom coils with smaller dimensions than traditional coils. Our proven techniques make tight tolerances, non-standard winds, tight radii, short overall lengths, and very specific pitches and diameters achievable. Whether your custom coil requires just a few turns or a few thousand, we have the expertise to deliver.

Request a quote on custom coil products, or contact HBR for more information.

Coil Winding to Meet YOUR Requirements

We are open to any design ideas our customers may have. Our coil winding capabilities include odd, non-standard shapes and a wide variety of other unique characteristics.

HBR works with wire gauges from 2 to 42, so we can produce your next project no matter how complex your design may be, or how tight the tolerances required, we welcome the challenge. HBR Industries specializes in turning customer designs into tangible products. We are open to any design ideas our customers may have.

What is coil winding?

The wire or conductor which constitutes the coil is called the winding. ... Each loop of wire is called a turn. In windings in which the turns touch, the wire must be insulated with a coating of nonconductive insulation such as plastic or enamel to prevent the current from passing between the wire turns."--

Coil Winding Material Options

We work with both round and flat wire in our custom coil bending and winding processes. We also possess a wide range of standard and specialty gauges to meet your needs. We carry numerous types of materials, including:

Our manufacturing expertise enables us to produce custom wound coils that exceed the standard industry callouts of the materials used. With our in-house fixturing capabilities and strategic partnerships with area machine shops, we can produce the tooling and fixturing needed to manufacture high precision, custom coils that perfectly match your specifications.

Copper Coiling Benefits

Copper coiling and coil bending services are well-suited for RF applications. Copper coiling can also transmit liquids, air, or other media to cool equipment of all types. When properly applied, copper coil winding (water coiling) can function conductively and simultaneously as a cooling coil. No matter what your application, HBR can create ideal copper coiling for your coil bending and winding needs.

Coil Options for Coil Bending & Winding

Coils used for coil winding and bending applications can be classified by the frequency of the current they are designed to operate with, these frequencies include:


  • Direct current or DC coils or electromagnets operate with a steady direct current in their windings
  • Audio-frequency or AF coils, inductors or transformers operate with alternating currents in the audio frequency range, less than 20 kHz
  • Radio-frequency or RF coils, inductors or transformers operate with alternating currents in the radio frequency range, above 20 kHz

Electromagnetic Coil

An electromagnetic coil consists of two distinct elements, a conductor and a core. The conductor is usually made from copper wire and is wrapped around the core. One cycle around the core is called a turn. When the wire is turned multiple times it’s considered to be a coil. The role of the coil is to provide inductance to an electric circuit. Inductance is an electrical property characteristic to electromagnetic coils opposing the flow of current through the circuit.

What Is American Wire Gauge (AWG)?

American wire gauge (AWG), also known as the Brown & Sharpe wire gauge, is a standardized wire gauge system used since 1857 predominantly in North America for the diameters of round, solid, nonferrous, electrically conducting wire.  The cross-sectional area (diameter) of each gauge is a principal factor for determining its current-carrying capacity. Some important aspects of AWG, include:

  • Increasing gauge numbers denote decreasing wire diameters
  • The AWG tables are for a single, solid, or round conductor.
  • When the cross-sectional area of a wire is doubled, the AWG will decrease by 3. This doubles the ampacity.
  • When the diameter of a wire is doubled, the AWG will decrease by 6. This quadruples the cross-sectional area and the ampacity.
  • A decrease of ten gauge number reduces the electrical resistance and increases the conductance by a factor of approximately 10.
  • For the same cross section, an aluminum wire has a conductivity of approximately 61% of copper, so an aluminum wire has nearly the same resistance as a copper wire 2 AWG sizes smaller, which has 62.9% of the area.

American Wire Gauge’s (AWG) Precision Benefits

HBR Industries values the need for an in-depth understanding of wire gauges, and what those differences mean regarding your requirement needs. Properly deciphering wire gauge sizing and knowing what gauge of wire you need can often be a tricky task. That is why HBR Industries, Inc., based on each individual client’s needs and requirements, utilizes the AWG chart as the guideline for all wire related projects.

The shared AWG chart below is based off bare-no film wires. We also have the capabilities to do work with other wires with coating or film, contact us to find out more.

Coil Prototypes, Design Assistance & More

At HBR Industries, Inc., we do more than just standard production runs. We can also create prototype parts and components to test fit, form, and function, along with one-off pieces for your specialized application.

We can work with you, as needed, to enhance your part designs for improved performance or better manufacturability. If you’re not sure which material is best for your needs, if your design dimensions are not quite right, or if you need any help in any capacity to make your parts work or fit the way you need them to, we offer design assistance through our close network of vendors.

Contact HBR To Learn More About Custom Coil Bending and Winding Services Today!

The HBR team will work with you to develop the perfect custom coil solution for your project needs. Our custom coil bending and winding expertise provides almost unlimited possibilities. Request a quote on the custom coil products you need, or contact us to learn more.