Crank Shaft IH Coil Technologies

Fuji-Denshi Induction Coil Manufacturing Philosophy.

Our philosophy is to design the optimal inductor shape based on the customer’s required quench-hardening quality and expected hardening conditions. Each copper part is produced using the most suitable manufacturing method, then assembled into a single inductor. Rather than shifting from hand-made to 3D-printed inductors, FD has adopted each method in chronological order to improve performance and reliability.

Hand-Made Copper Components

The hand-made method of coil building relies on bending copper pipes by hand, a process that emphasizes craftsmanship and experience.

  • Hand-made coil building involves bending copper pipes by hand.
  • Coils are shaped with precision to meet hardening requirements.
  • Advantages: time and cost savings for simpler designs.
  • Limitation: challenging for complex shapes, requiring expertise and patience for consistency.

Machining Copper Components

Machining coils uses advanced technology to create induction coil parts greater precision and complexity than hand-made coils.

  • Enables intricate shapes and exact tolerances for consistent results.
  • Offers high flexibility, accuracy, and performance.
  • Drawback: more time- and cost-intensive than hand fabrication.
  • Best for parts where complexity and reliability are priorities over speed.

Lost-Wax Copper Components

Lost-wax casting produces precise, intricate copper parts with minimal waste.

  • Reduces excessive machining and lowers production costs.
  • Combines traditional craftsmanship with strict process control.
  • Skilled technicians ensure accuracy from wax model to final casting.
  • Limitations: long lead time and low flexibility.
  • Less suited for rapid design changes or custom adjustments.

3D Printed Copper Components

Additive manufacturing uses 3D printing for precise copper parts with minimal labor.

  • Shorter lead times compared to lost-wax casting.
  • Eliminates vulnerable areas (e.g., brazed joints) for greater durability and reliability.
  • Skilled operators and advanced equipment ensure consistent quality.
  • Drawback: high raw material costs.
  • Less cost-effective for large-volume production.