Micro soldering refers to join wires with a diameter of 9 microns which are much thinner than a human hair. This process is done using a metallic alloy to mold and melt two metals together. This process is achieved by using a metal with a lower melting point.

Over the last three decades, the world has developed rapidly, as if on steroids. The medical field has also experienced exponential growth.This growth has led to the rise in demand for miniature medical devices which are manufactured using miniature micro coils. These micro coils made of wires in-turn are produced through micro soldering. Manufacturers that produce micro coils have to possess the technical knowledge in micro soldering methods. This process involves winding micro wires into micro coils which are used to make sensors in miniature medical devices.

The micro wires that are used are subject to strict regulations and have to handle many challenges that they will be exposed to. These strict regulations limit traditional welding methods from being used. Traditional methods used in welding can’t handle the extreme micro-wires that are used especially for medical purposes.

Traditional methods used in soldering

Traditional soldering uses the following two methods.
• Welding and melting of two metals that need to be joined using electricity.
• Use of external heat to heat a filler that is used to join the two metals.
They cannot use the traditional methods mentioned above in soldering micro-wires since they produce residue and have other constraints.

The following are some issues traditional welding methods create:

• Traditional welding methods create wires that degrade over time because of physical constraints causing unreliability.
• The methods used in traditional soldering causes wires to oxidize and infecting the area around the wire.
• Traditional welding methods can’t produce even heat during the welding process, which produces defective wires.

The issues that traditional soldering methods create makes these traditional welding methods ineffective in micro coil production. The solution to these issues is to use advanced and unique micro soldering methods intended for micro wires. Manufacturers involved in micro soldering can melt and mold wires that are very fine irrespective of the material used or the diameter of the wires.


Manufacturers make use of thermos pressure technology for:

• This technology is used to connect wires that are very fine copper thermocouples.
• Thermospressure is used in the support system of micro coils using metal plated terminals.

Manufacturers that use this innovative method can produce micro wires that are more reliable and are not corrosive. This method of production is also cost effective and is capable of mass production while ensuring high regulatory standards.

Micro soldering is a relatively new field that has exponential potential. Micro soldering is especially vital in the medical field where the demand for miniature medical devices will continue to rise. Manufacturers that create unique methods to mold micro wires together will continue to be ahead of the curve.