A new advancement in physics, bifilar coil winding, is the latest answer to a smooth and efficient flow of energy in varied devices. Compared to a wire-wound resistor that has developed many challenges like its shape and size to the lack of tolerance over the years, bifilar coil winding is what you could say a breath of fresh air. 

Simple physics describes coils’ formation as spiraling a wire with the capacity to conduct electricity in the form that’s desired. As minute as it sounds, the process considers various aspects, including the wire’s resistance, strength, and induction, among other variables while constructing it. Bifilar coil winding follows a similar pattern only here, and the coil is not made from one rather, two closely spaced conductors. In the neighboring coils, the current flow in both these wires is in the same parcel direction. At the same time, the wound conducts electricity in the opposite direction. But how does this make a bifilar coil winding any special? 

Since the current flow in one coiled wire in a similar direction to the other, the magnified field conducted is zero. Any negative emission or fallout from the Magnetic field happens with a wire-wound resistor cancels in bifilar coil windings. 

That’s about the winding, but there is more. Some institutes have come forward with innovation in the way these coil winding connect as well. A tin-based solder has been used as the base for such connections up til now; with the advent of bifilar coil winding, the connectivity has been upgraded with a high presence solder. This solder is highly efficient and uses thermo-pressure technology giving the coil and the connectivity higher tolerance and longer life. 

This process has become a tremendous help in ways never thought before


  • Bifilar coil windings are much more robust and devote a longer life span inside the device used. 
  • Since the entire process is very precise, the use of robotic technology is paramount. Replacing the manual workload, these robots can work round the clock, effortlessly. In other words, cutting costs. 
  • The coils can also work effortlessly at higher temperatures without infringing. 

This technology is widely seen in varied devices at your home, including your laptop charges, USB devices, and various other cables requiring the flow of electricity in parallel or opposite directions. However, the technology still needs to cross several barriers before it is seamlessly used in devices. 

Some of them include:

  • The requirement of robotic technology that can perform such intricate tasks. 
  • The need for mass production to save cost. 
  • No compromise on the durability and quality of the coils. 
  • We need to reduce the number of human errors to enhance precision. 
  • The coils’ size is a major issue for both the manufacturing process and its application in varied devices. 

These and many similar technological and manufacturing issues still pose a challenge in successfully applying bifilar coil winding. But, many more variables point towards success for the mechanism. 

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