Direct Adhesive™

The patented Direct Adhesive™ technology allows highly automatic manufacture of complex, multi-layer 2- and 3-dimensional wire forms. In this assembly process, a computer controlled multi-axes machine accurately positions the conductor and bonds it onto a support structure and consecutive layers. Based on AML’s CoilCAD® design software, complex coil designs are optimized and then converted to machine coordinates which define the conductor along a three dimensional path.

Along with software and automated manufacturing, AML incorporates special developed adhesive for “attaching” the conductor real-time. This process dramatically reduces R&D and product development cycles. Direct Adhesive™ eliminates the need for mandrels, fixtures, tooling and coil potting or vacuum impregnation. The end result is a flexible, cost effective, and high quality process.

Unique coil patterns are enabled by Direct Adhesive™ including curved geometries for both flat and cylindrical coils. This includes not only nesting wires from layer to layer, but also “stacking” to optimize coil density while still maintaining very precise windings. These coils can be wound either off-line or directly onto the magnet structure. These precision coils provide very high field quality even with very complicated geometries.