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Microfusion: Innovative Technology for Inductor Manufacturing

Patented Process Delivers Increased Inductor Repeatability and Durability

a microfusion inductor (left) vs. a traditional copper coil (right)One of the most important aspects of an induction heating machine is the inductor itself. GH Group has patented a revolutionary new system for inductor design and manufacturing using exclusive microfusion technology. Traditional inductor manufacturing is a one-off process – the raw material is shaped by hand to
conform to engineering specifications. This makes it exceptionally difficult to manufacture absolutely identical inductors with the same performance characteristics.

With GH microfusion technology, identical inductors can be produced from the same manufacturing mold. This increases repeatability and consistency when multiple induction systems are running the same process, and significantly reduces maintenance and calibration time when inductors need to changed.

Advantages of Microfusion

Repeatability – Multiple inductors can be made from same pre-qualified mold with high dimensional accuracy - 0.1 to 0.25 mm of tolerance. The ability to manufacture and supply identical replacements ensures that heating profiles are maintained when fixtures are changed, and eliminates the need for recalibration.

Durability – Our microfusion inductors have increased cooling efficiency and are made from a compound 25% more conductive than copper. With one-piece construction, weak points from weld or braze joints are eliminated. With 3D design, both interior and exterior paramers can be tightly controlled. The areas where current is passed through are improved

Increased Production Rates – Microfusion inductors have a longer working life, reducing production stoppages for fixture changes. And when the inductor does need to be replaced with a new but identical fixture, maintenance and recalibration time will be minimized.

Reduced Inventory Requirements – Because microfusion inductors have a longer working life, and delivery times for replacement orders are reduced, you'll
need to carry fewer spares in your inventory.

Complex inductor shapes made easier – With microfusion, it is possible to manufacture very complicated inductor designs, that simply were not possible to produce with classic methods.

How the Process Works

The manufacture of inductors with GH microfusion technology is a three-step process:

  • Obtaining a solid for the process involves two channels: design in a 3D program and 3D scanning (see Figure 1 below)

  • 3D resin printing of the manufacturing mold (Figure 2) via stereolithography. This technique is based on the possibility of solidifying a liquid state resin by projecting a laser beam of a very specific frequency and power. The laser follows the surface of the section and its surroundings. The liquid is a photopolymer that solidifies when it is exposed to hi-energy light. The result is a perfect prototype copy of the 3D original design, including the cooling channels of the inductor and the added casting channels.

  • Obtaining the finished coil by means of the patented microfusion process (Figure 3). The process involves coating, sintering, casting, demolding and cleaning.

        How the microfusion process works

We are also capable of producing inductors for hardening and tempering installations of manufacturers other than GH manufacturing. Contact us today to learn how we can put this innovative, patented process to work for you!

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