Microfusion
Innovative Technology for Inductor Manufacturing
Patented Process Delivers Increased Inductor Repeatability and Durability
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:
- There are two inductor design options: design in a 3D program for new inductors, and 3D scanning for existing inductors (see Figure 1 below)
- 3D resin printing of the manufacturing mold (Figure 2)
- Obtaining the finished inductor by means of the patented microfusion process (Figure 3)
Will a Microfusion Inductor Design Work for You?
This new design technique can be employed for inductors used to manufacture crankshafts, tripods, wheel hubs, camshafts, steering racks, valves, rocker arms, clutches, C.V. joints, bearings, gearing, as well as railway rails and wheels.
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!
585.368.2120
Microfusion inductor (left) vs. a traditional copper coil (right)
Complex inductor designs are possible with microfusion technology.