The fantastic four

At Flux, we crimp, weld, strip, and pot. Our factory in Bangkok, Thailand, houses approximately 250 industrial workers who manage contemporary production equipment daily. Flux is a supplier of magnetic components to various sectors including the renewable sector, the automotive sector, the Space & Defence sector as well as industrial applications.

At our Thailand facilities, we implemented the four processes: hot crimping, laser welding, laser stripping, and vacuum potting to be more flexible and effective in terms of production. When investing in new technology, we constantly improve our knowledge and machining abilities within these procedures as we pride ourselves on staying experts on these specific processes.

Hot crimping

With hot crimping, we join metals via a metal-joining technology that uses electrical current and mechanical pressure to connect conducting electrical wires. Hot crimping differs from other types of resistance welding as it uses conductive metal sleeves when passing the electrical current; generating heat to hold the wires together. Essentially, hot crimping relies on the heat generated by the electrical resistance of the welded material as well as the force that is used to hold the materials together during the welding process. As seen in the video below, our machinery joins the metal piece that surrounds the electrical wires using electrical current and mechanical pressure.

Laser welding

Our laser overlay and welding devices can weld and cut metals of any size. The adjustment options of our machines make them great for larger as well as smaller workpieces. The adjustable lens rotates 360 degrees and can be adjusted to any angle, making the welding procedure much more agile in terms of precision. With this process, every safety precaution is made when our employees weld the workpieces using our laser welding devices. 

Laser stripping 

Simply put, when removing the insulation that covers the electrically conducted wires, we use a technical technique called laser stripping. Laser stripping is fast, and the process is extremely precise and easy to control. In general, laser wire stripping eliminates any contact with the wire, meaning that any risk of damaging the conductor of the wire shield is avoided.

Potting

Traditional potting is a process where elements are cast into plastic or metal houses, the elements then solidify and secure a complete casting which contributes to isolating abilities. See an example of traditional potting below.

Vacuum potting

Vacuum potting is the new and improved version of traditional potting. Essentially, the procedure is the same. With vacuum potting, however, the elements are potted under vacuum pressure at zero – this causes the casting material to enter even the smallest spaces. With no or little pressure, it becomes easier for the casting material to enter every cavity of the processed element.

Quality is key

As the product line is practically finished, a few ultimate steps need to be followed to conclude the production process. Besides all the flexible automation, Flux also employs several automatic actions to control the quality. These automatic actions include an automatic visual inspection to analyze if the elements look satisfactory. Next, the elements go through fully automatic testing. With automatic height testing, a laser measurement ensures that the height of the components is right. The electrical testing makes sure the components fully meet the electrical properties and characteristics specified by the customer. The automatic testing enables us to quality-proof the objects, testing if they work as desired before sending them on to our customers.

See below how we test our components in terms of height- and electric features in the final production phase.

Height testing

Electric testing

Flux delivers magnetic components to various sectors including the renewable sector, the automotive sector, the Space & Defence sector, and the industrial applications – all of which need flawless components that work the first time around. That is why we emphasized the inspection step to avoid sending faulty components to our customers.

As technology is constantly exposed to innovation and renewal it is crucial that we invest in the newest means of technology and innovative contributions to allow for growth and expansions whilst staying competitive in terms of market requirements and demands. Therefore, we’re constantly investing in the newest machines and technology.

Wish to know more about these specific processes? Get in touch with John Willum, our COO of Industrial & Automotive, to get more information about how these processes can be implemented according to your needs.