Case Study for Encapsulation Molded Coil

An illustration of our product development process presented as a case study.

Encapsulation Molded Coil


flextech-meeting-custom-foam-productWe were contacted by a medical device company that was developing an implantable electronic device, similar to a pacemaker, which would be used to treat obesity. They wondered if we might be able to provide a solution for an application they had where they needed to enclose an electro-magnetic charging coil for the device, in materials that needed to be comfortable and safe when in contact with a patient’s body.

When working on the development of a new product, Flextech encourages early involvement at the project’s onset. This customer understood the value of collaborating with a manufacturing partner early in the design and development process. In an effort to fully understand the functional and aesthetic requirements of the coil application, one of our technical sales representatives met with our customer’s product managers and engineers. Our sales person learned that the implantable device would stimulate the vagus nerve and cause the patient to feel less hungry.

Because the device is implanted in the body, it would need to be charged regularly using a process called inductive or “wireless” charging.  An inductive electromagnetic coil would be worn by the patient over the location of the device for a required period of time in order to charge the device.  The coil would need to be covered by a material that was comfortable to the patient, biocompatible and non-cytotoxic (safe for contact with human skin). It also required some method of securing it to the patient for the duration of the charging cycle.  In addition, because it is a medical device, the coil assembly would have to have a clean, finished appearance.

We were challenged by our customer to develop a process, suggest appropriate materials, and to manufacture a part to meet all of these functional and aesthetic requirements.


sewn-coil-conceptOur R&D engineers suggested a different solution.  We proposed that we utilize our ENCAPSULATION MOLDING process wherein we would encapsulate the electromagnetic coil in the foam molding process.  This process would eliminate the need for secondary sewing and wouldn’t require the use of sewn textiles that might absorb perspiration or other body fluids.  We were also able to incorporate formed and sealed slots in the part so that the belt that holds the coil in place could be threaded through the part. The slot features eliminated the need for any supplemental hardware. In addition, the final assembly’s aesthetics would make it look like a medical device. We provided the customer with 3D part models and images of the coil assembly that we were proposing.

Our customer was very excited about our product design.  They asked that we offer material options and provide quotations on the tooling and piece prices so that they could determine if our improved product design was economically viable.


cadThe tooling and piece prices we provided our customer with were acceptable to them, and they asked that we continue the development process.  Because the charging coil needed to be comfortable when worn by the patient, we suggested a low density 2 lb/cubic foot cross-linked polyethylene foam.  More importantly, the coil enclosure also needed to be covered by a material that was approved for medical skin contact and that would not absorb body fluids.  We discussed the application with our material suppliers and ultimately suggested a urethane coated textile that had been tested to meet ISO 10993, which is the medical standard for materials that come in to contact with intact skin.

Once these materials were approved by the customer, we focused on the design of the tooling and fixtures that we would need to heat and mold the composite and encapsulate the coil during our ENCAPSULATION MOLDING process.


gal-encapsulation-molding-4Our engineering team went to work designing the tooling and fixtures we would need to build functional prototypes for our customer to evaluate and test. This project required the use of machined aluminum tool components in order to achieve the part geometry and definition the customer required.

In addition, we had to design and build fixtures that would allow us to register and secure the electro-magnetic coils during the ENCAPSULATION MOLDING PROCESS. Because this project would require us to laminate the urethane coated healthcare fabric to a closed-cell foam, we performed some preliminary testing of the LAMINATING process to make certain the fabric and foam would bond sufficiently to then be molded. We achieved a functional lamination bond of the two substrates and now had materials prepared for the completion of the tooling.

The prototype development process usually requires experimenting with the raw materials and process parameters and that was the case on this project. Once our tool shop completed the assembly of the tool, our R&D team was able to experiment with the required oven temperature, heating cycle, press tonnage and dwell time in order to encapsulate and seal the coil in the fabric and foam composite.

Ultimately, we were able to ENCAPSULATION MOLD a prototype coil assembly that we believed would meet our customer’s requirements.  We provided several coil assemblies to our customer for their evaluation and testing.  The coil assembly functioned as required, and following a few design iterations our customer was ready for us to manufacture the assemblies in volume and with production tooling.


Encapsulation-Molded-Col-Unit-Production-ToolFollowing several months of testing, the ENCAPSULATION MOLDED coil assembly was approved for production by our customer. In order to scale up for the manufacturing of larger quantities of coil devices, we needed to build multi-cavity production tooling and registration fixtures.  Once the production tooling and fixtures were built, we provided first articles for our customer’s final approval.

In order to ensure that we provided our customer with quality coil devices, we also needed to develop a quality control program for every step of the manufacturing process.  Utilizing our ISO 9001:2015 certification as a framework, we tailored a quality control process for this unique device assembly.   We were then prepared to produce production quantities of coil assemblies for our customer’s product launch.

Project Outcome

Encapsulation-Molded-Electromagnetic-Coil-production-deliveryThe success of this joint product development effort between Flextech and our customer in the medical device market serves to illustrate the benefit of early collaboration when developing a new product.

Connecting and collaborating with Flextech in the initial stages of the device design allowed us to optimize the product development timeline. Our thorough understanding of the functional and aesthetic requirements of the device early in the process gave us the information we needed to provide concepts and designs that would be of interest to our customer.

After a design was approved, we were then able to engineer and develop a manufacturing process and specify materials suitable for the device construction.  Armed with all of the information that our customer shared with us initially, we were able to minimize the number of design iterations during the prototype and prove phase of the development cycle.

Finally, once our customer tested and approved our prototype parts, we were able to scale up our manufacturing process and produce and deliver quality coil assemblies.

Contact us

Please contact Flextech if you have an idea for a new product you would like to develop, or a problem you would like our sales and engineering experts to help you solve. We look forward to an opportunity to work with you.

Situs Togel 4D Bo Togel Bandar Togel Deposit Pulsa Agen Togel Deposit Ovo Togel Bet 100 Perak Bandar Togel Terbesar Toto Togel Bandar Togel Daftar Bandar Togel Terbesar agen togel deposit ovo situs togel 4d Slot Bonus 100 Situs Judi Slot Terbaik Slot Gacor Slot Pragmatic Link Slot Gacor Dingdong Togel Slot Deposit Pulsa Situs Slot Judi Online Agen Slot Online BO Togel 5 Bandar Togel Terpercaya Togel 100 Toto Togel Agen Togel Resmi Bandar Togel Deposit Pulsa Dingdong Togel Situs Togel Terbesar Bandar Darat Togel Togel Toto Online Togel Singapore BO Togel Bet 100 Perak Agen Togel Deposit Pulsa Situs Bandar Togel Hadiah 4D 10 Juta 10 Situs Togel Terpercaya 5 Bandar Togel Terpercaya Situs Slot Deposit Pulsa Agen Slot Online Togel Hari Akun Slot Bet Game Situs Judi Slot Situs Judi Slot Resmi Game Slot Slot Game Bonus New Member 100 Agen Togel terpercaya 10 Situs Togel Terpercaya Agen Togel Online Agen Togel Singapore Togel Toto Macau Situs Togel Terpercaya 10 Situs Togel Terpercaya Situs Bandar Judi Togel Situs Togel BRI Online 24 Jam situs togel dan slot SITUS TOGEL DEPOSIT VIA DANA situs togel terbaik 5 bandar togel terpercaya bandar togel hadiah 4d 10 juta terpercaya BANDAR TOGEL HADIAH 4D 10 JUTA Situs Slot Bet 100 Perak situs bandar togel terpercaya Bandar Togel Deposit Pulsa Situs Slot Situs Slot deposit Pulsa Agen Slot Dan Togel Toto Slot Bandar Togel Hadiah 4D 10 Juta Situs Togel Online Situs Slot Togel Terlengkap Agen Slot BO Togel Agen Togel Online Situs Bandar Togel Dan Slot Situs Togel Togel Deposit Pulsa Slot Gacor Bandar Togel Lengkap Situs Slot 5 Bandar Togel Terpercaya Bo Togel dan Slot 5 Bandar Togel Terpercaya Judi togel Togel Hadiah 2D 100rb Bandar Togel Dan Slot Togel Bet 100 Lotre Togel bandar darat togel 5 bandar togel terpercaya Situs Togel Terpercaya bandar judi terpercaya Bandar Togel Terbesar Bandar Togel Online bandar togel bandar togel terpercaya hadiah terbesar judi togel bandar togel terbesar situs judi online bandar togel terbesar Togel Online Bandar Togel Bolak Balik Dibayar Bandar Togel Lengkap situs togel Bandar Togel Togel Hadiah 4d Terbesar bandar togel hadiah terbesar Bandar Togel Hadiah 4d Terbesar judi togel Togel Online Terbaik Situs Togel Terbesar Bandar Lotre Togel Togel Kamboja Dingdong Togel Bandar Togel Terbesar dan Terpercaya Bandar Togel Terpercaya Daftar Bandar Togel Togel Deposit Via Dana 5 Bandar togel terpercaya agen togel terpercaya slot online Situs Bonus New Member Slot Gacor 10 Situs Bandar Togel Slot Online Agen Slot Online Slot Pragmatic Slot Pragmatic Agen Togel Lengkap Bandar Togel Hadiah 4d 10 Juta Slot Resmi Bo Togel Situs Togel Terpercaya 5 Bandar Togel Terpercaya Agen Bo Togel Bandar Togel Slot Pragmatic Judi Slot Pragmatic agen togel online Agen Togel Terpercaya toto togel 5 Bandar Togel Terpercaya Bandar Togel Terpercaya Bandar Togel Online Situs Togel Resmi Agen Slot Judi Slot Online 10 Situs Togel Terpercaya Slot Pulsa Tanpa Potongan Situs Slot Gacor Bo Togel Togel deposit pulsa Agen Judi Slot Online Terpercaya Situs Slot Gacor Mesin Slot Bandar Togel dan Slot Agen Judi Slot Pragmatic Slot Online Via Dana Link Slot Gacor Situs Game Slot Online SITUS SLOT ONLINE GAME SLOT Agen Togel Terpercaya Bandar Togel Slot Bandar Togel dan Slot Bandar Togel Terpercaya Hadiah 4d 10 Juta Bo Togel Bandar Togel Deposit Pulsa Bandar Togel Terpercaya Bandar Togel Hadiah 2d 100rb Slot Pragmatic 5 Bandar Togel Terpercaya Bandar Darat Togel Bandar Togel Dan Slot Bandar Togel Hadiah 2d 100rb Bandar Togel Hadiah Terbesar Bandar Togel Lengkap Bandar Togel Online Bandar Togel Terbesar Daftar Bandar Togel Tertua Agen Slot Bonus 100 Agen Togel Mesin Slot BANDAR TOGEL HADIAH 2D 100RB Bandar Togel 77 TOTO SLOT 5 Bandar Togel Terpercaya 5 Bandar Togel Terpercaya 2022 Situs Judi Slot Terbaik Bandar Darat Togel Bandar Lotre Togel Bandar Togel Bet 100 Rupiah Bandar Togel Bet 100 Bandar Togel Hadiah 4d 10 Juta Terpercaya BANDAR TOGEL HADIAH 4D 10 JUTA BANDAR TOGEL TERPERCAYA HADIAH TERBESAR Bandar Togel Terbesar BANDAR TOGEL LENGKAP Bandar Togel Hadiah Full Togel Online Bandar Togel Resmi Bandar Togel Terbesar Situs Slot Online Bandar Judi Slot Online Daftar Bandar Togel Tertua BANDAR TOGEL TERPERCAYA AGEN JUDI SLOT ONLINE TERPERCAYA DAFTAR JUDI SLOT ONLINE Slot Pragmatic BO JUDI SLOT ONLINE DAFTAR SITUS SLOT GACOR Nama Nama Situs Judi Slot Online Terpercaya Togel China Bandar Judi Slot Online SITUS JUDI SLOT DEPOSIT PULSA Situs Slot Deposit Pulsa Togel Kamboja Agen Togel Resmi AGEN SLOT ONLINE Slot Bonus New Member 100 LINK BO TERPERCAYA SITUS SLOT GACOR Slot Gacor Agen Judi Slot Online Resmi DAFTAR NAMA NAMA SITUS JUDI SLOT ONLINE AGEN TOGEL RESMI DEPOSIT PULSA Agen Judi Slot Gacor SLOT ONLINE KUMPULAN NAMA SITUS SLOT ONLINE TERPERCAYA Bandar Togel dan Slot GAME SLOT ONLINE Togel Bandar Darat BANDAR TOGEL TERBESAR TOGEL HADIAH PRIZE 123 BANDAR TOGEL TERPERCAYA Agen Slot Online Situs Slot Deposit Pulsa Situs Judi Online Situs Slot Online Situs Judi Togel Situs Judi Slot Online Terpercaya 5 Bandar Togel Terpercaya Toto Slot Agen Judi Slot Online Situs Slot Terbaru Togel Deposit Pulsa Slot Online Situs Judi Slot Online Terpercaya Slot Pragmatic Bandar Togel Bet 100 Perak Situs Slot Slot Deposit Pulsa Slot Mpo Situs Judi Slot Online Slot Online Terbaik dan Terpercaya Game Slot Agen Slot Pulsa Slot Gacor Agen slot dan Togel Agen Judi Slot Online Terpercaya Togel dan Slot Agen Togel Slot Gacor Slot Gacor Agen Judi Slot Online24Jam Slot Gacor Judi Online Judi Slot Online Bo Togel Slot Online Sultanplay Situs Judi Slot Online Situs Mpo Slot Gacor Slot PG Soft Slot Online Sultanplay Agen Judi Slot Online 10 Situs Togel Terpercaya 10 SITUS TOGEL TERPERCAYA Slot Online Terpercaya Joker Slot Bandar Togel Dan Slot Bandar Togel Hadiah Full Bandar Togel Hadiah Terbesar Bandar Togel togel Togel Macau Togel Kamboja Slot Deposit 5000 Slot Terpercaya Togel Singapura Toto Macau Nama Nama Situs Slot Online Bandar Togel Kamboja Bandar Togel Terpercaya Togel Hadiah 4d 10 Juta Terpercaya Agen Slot Agen Judi togel Resmi Situs Togel Terpercaya Situs Togel Terbesar Bandar Toto Terpercaya Agen Slot Gacor Togel Hongkong Judi Slot Online Hondatoto Ojktoto Slot Online judi togel Bandar Togel Togel Bet 100 Rupiah Slot Online Situs Togel Terpercaya Bandar Togel Terpercaya SITUS TOGEL RESMI Situs Togel Terpercaya Situs Togel Terbesar 10 Situs Togel Terpercaya Situs Togel Situs Togel Resmi Bandar Togel Situs Togel Terbaik Situs Togel Deposit Pulsa Togel Online Situs Togel BANDAR JUDI TOGEL Bandar Togel Online Daftar Bandar Togel Terbesar dan Terpercaya Situs Togel Resmi Togel Terpercaya SITUS TOGEL TERBESAR DAN TERPERCAYA Situs Togel Terpercaya 10 Situs Togel Terpercaya Situs Judi Togel Nama Situs Togel Terpercaya Situs Togel Situs Togel Terpercaya Bandar Togel Resmi BANDAR TOGEL TERBAIK Bandar Togel Terpercaya Togel Hadiah Prize 123 BANDAR TOGEL RESMI Bandar Togel Terbaik Bandar Togel Terpercaya Mesin Slot Bo Togel Bandar Togel Resmi DAFTAR BANDAR TOGEL TERBESAR DAN TERPERCAYA Bandar Togel Terpercaya Slot Online Bo Togel Togel Seratus SITUS TOGEL Togel Terpercaya Slot Gacor togel online Situs Togel Bandar Togel Terpercaya