Magnet Wire to PCB Pads

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System 1:
Sunstone CD100SPM, 100ws CD resistance welder
MWH Parallel Electrode Holder (not pictured)
Thermo-compression electrode (precision tip)
8awg weld cables

The three sizes of magnet wires were welded to the PCB using a CD100SPM power supply unit coupled with an electrode holder from an MWH1000 parallel micro weld head (removed from the weld head and used in a hand-held manner). We used a thermo-compression electrode to help melt away the coating on the magnet wire during the weld. Electrode placement is important for good weld strength and hand pressure can be difficult to control so we highly recommend using a weld head to apply force instead of using operator hands in order to achieve repeatable consistent welds. The operator will need to experiment to find the right amount of force to apply by hand for each wire size and try to duplicate that hand force each time.

Wires were welded using the following settings:
56awg -- 4.8ws Energy, Max Length
53awg -- 5.0ws Energy, Max Length
50awg -- 5.1ws Energy, Max Length

Resulting welds were strong enough to hold the weight of the PCB without breaking. Further experimentation with settings and refinement of the application of hand pressure will improve weld quality and strength.


Summary:

The CD100SP and hand-held electrode holder with thermo-compression electrode are capable of welding all three sizes of magnet wire to a PCB. Operator hand pressure becomes important in this configuration. We recommend a DCD320 power supply and MWH2000 parallel weld head for more precise and repeatable welds but the CD100SPM is an acceptable alternative.

Let us know if you have any questions.
Call or Text: +1-801-658-0015
Email: [email protected]
Website: https://SunstoneWelders.com