Induction coils are at the heart of many industrial processes, from heat treatment and brazing to forging and annealing. Traditionally, these coils are manufactured through labor-intensive methods like brazing and bending copper tubing — processes that can limit design complexity and lead to inconsistencies in performance. Today, metal additive manufacturing (AM) is transforming the way induction coils are designed and produced, offering a range of benefits that enhance performance, efficiency, and durability.

Design Freedom and Enhanced Performance

One of the most significant advantages of metal AM is the design freedom it offers. Traditional manufacturing techniques often constrain the geometry of induction coils, but with AM, complex internal structures and optimized coil designs become possible. This freedom allows manufacturers to:

• Optimize magnetic fields for more efficient energy transfer.
• Incorporate cooling channels directly into the design to improve thermal management and extend coil lifespan.
• Reduce weight while maintaining structural integrity, thanks to advanced design techniques like lattice structures and topology optimization.

By leveraging metal AM, induction coil designs are no longer bound by the limits of traditional manufacturing, paving the way for more efficient and reliable coils that improve overall system performance.

Faster Production and Reduced Lead Times

In traditional manufacturing, producing induction coils involves multiple steps — cutting, bending, brazing, and assembling. Each step adds time and complexity to the process. Metal AM streamlines production by printing coils directly from a digital model, reducing the number of steps and minimizing the need for post-processing. This translates to:

• Shorter lead times for custom or replacement parts.
• Rapid prototyping to test and refine designs before full-scale production.
• On-demand manufacturing, ensuring critical parts are produced exactly when needed.

The ability to produce custom induction coils quickly and efficiently not only reduces downtime but also allows for greater agility in responding to shifting production demands.

Material Efficiency and Cost Savings

Copper is the material of choice for induction coils due to its excellent electrical and thermal conductivity. However, copper is expensive, and traditional manufacturing methods generate significant material waste. Metal AM minimizes this waste by building coils layer by layer, using only the material required for the part. This leads to:

• Lower material costs by reducing waste.
• Increased sustainability with more efficient use of raw materials.
• Cost-effective production of complex parts, even for low-volume or custom runs.

The ability to produce high-performance copper coils with minimal waste makes metal AM a more sustainable and economical option for induction coil manufacturing.

A New Era of Copper AM in the U.S.

Metal additive manufacturing (AM) is transforming induction coil production by enabling complex designs, faster manufacturing, and reduced material waste. With AM, coils can be optimized for better performance, incorporating features like internal cooling channels and lightweight structures. This technology streamlines production, cutting lead times and boosting efficiency — especially when working with high-value materials like copper. Tucker Induction Systems is leveraging an SLM®280 PS to push innovation in copper AM. Learn how this partnership is reshaping the future of induction coil manufacturing.

Why Parther With Nikon SLM Solutions?

For companies looking to revolutionize their induction coil manufacturing, Nikon SLM Solutions offers metal AM systems designed to handle copper and other high-performance materials with precision and reliability. Our technology provides:

• Unmatched design flexibility for optimized coil geometries.
• Efficient powder handling systems for fast material changes.
• Expert support from our application engineers to help perfect your process.

Additionally, our Picture Perfect Pro Plan — available for the redesigned SLM®280, SLM®280 Production Series, and SLM®500 — ensures maximum productivity with an 85% machine uptime commitment, advanced software access, tailored powder supply contracts, and five years of Total Care Service. Whether you’re streamlining production, improving coil efficiency, or pushing the boundaries of induction system design, Nikon SLM Solutions gives you the tools — and the support — to make it happen.

Ready to take the next step in induction coil innovation? Let’s make it happen together.

To learn more about how Nikon SLM Solutions can help you optimize your manufacturing processes, please contact our team.