Winding electromagnetic coils by hand is a slow and challenging process, especially when you're trying to achieve neat, consistent turns for motors or actuators. To solve this problem, creator BubsBuilds designed an open-source automated coil winding machine that can produce custom coils based on specific project requirements. Originally built to support the development of a DIY linear motor, the machine gives makers an affordable way to create coils with different diameters, lengths, and turn counts without relying on expensive commercial equipment.
The machine combines an ESP32-S3 microcontroller, a 1.28-inch round display, a 12V geared DC motor, and a collection of custom 3D-printed components to automate the winding process. The display provides a simple user interface for controlling the machine and tracking the winding progress, while the motor ensures smooth and consistent rotation. One of the biggest engineering challenges was maintaining proper wire tension, which is critical for producing tightly packed, uniform coils. The creator carefully designed the spool mechanism to keep the winding consistent, resulting in cleaner and more reliable electromagnetic coils.
Another clever feature is the specially treated winding mandrel. Removing tightly wound coils often risks damaging the thin enamel coating on the copper wire, so the creator coated the mandrel with silicone and finished it with a PTFE release layer. This allows completed coils to slide off easily without sticking or damaging the wire. Released as an open-source project, the coil winder serves as a practical tool for makers interested in building custom linear motors, electromagnets, and other electromagnetic devices while showcasing how embedded electronics, mechanical design, and material engineering can come together to solve a real-world manufacturing challenge.
