Wiki article · Collection 03

Coil Cost Optimization

Engineering reference on Coil Cost Optimization for wireless power system design, integration, and deployment.

6 minArticle 49/50Coil Design

Coil Cost Optimization — educational diagram — Fig.: Educational diagram for “Coil Cost Optimization”.

Coil cost optimization balances copper/litz weight, ferrite tile area, potting volume, and process steps (hand vs automated winding). Saving on inner turns that contribute little to k but add disproportionate loss is smarter than uniform turn reduction.

Fleet programs feel cost through yield and field returns — cheapest coil that fails Rac screening is expensive at scale.

01Cost levers

Right-size OD to alignment spec, not oversized 'just because'.
Standard ferrite tile sizes vs custom cuts.
PCB auxiliary coils vs all-litz where power allows.
Modular design reducing unique SKUs across vehicle variants.

Coil Cost Optimization — supporting diagram — Fig.: Supporting illustration for “Coil Cost Optimization”.

02Guards

Any cost reduction must re-run thermal and misalignment power maps. Second-source litz requires Rac equivalence, not only gauge match. Do not drop Hi-Pot or sampling without reliability review.

03Total cost

Include pad downtime cost in serviceability design.
Tooling amortization for ferrite vs NRE on custom bobbins.
Logistics weight of ferrite-heavy pads for international installs.