In this Technical Tuesday installment, Josh Tucker, Manager of Induction Heating, Tucker Induction Systems, Inc., relates new research conducted on the strength of coils which have been produced through 3D printing.
This informative piece was first released in Heat Treat Today’s April 2025 Induction Heating & Melting print edition.
To read the article in Spanish, click here.
Research on 3D printing induction coils finds that coils are stronger and have a longer life when compared to traditionally manufactured coils. Read about how additive manufacturing removes steps like brazing the joints and provides new design capabilities.
Tucker Induction Systems began exploring the possibility of using 3D printing technology to manufacture coils and found that, in many cases, 3D printed coils were stronger and longer lasting than traditionally manufactured counterparts.
The quest to develop 3D printed coils began in 2020. When COVID-19 hit, Macomb County, Michigan, started an initiative called Project DIAMOnD, which stands for Distributed, Independent, Agile Manufacturing on Demand. It provided small-to-medium-sized area manufacturers with Markforged Fused Deposition Modeling-style 3D printers as both a way to quickly manufacture much needed personal protective equipment for the pandemic and to help small-to-mid-sized manufacturers overcome the supply chain issues that plagued industry during the crisis.
We were eager to gain hands-on additive manufacturing experience through the DIAMOnD initiative and, in doing so, found that it sparked our curiosity about the possibility of 3D printing our coils and new ways to design them that go beyond the capabilities of traditional machining.
In 2021, we began a two-year research and development process of printing coils and discovered that by 3D printing induction coils we were able to drastically increase the strength of the coils and potentially lengthen the useful life of the coil. The experience has opened new realms in designing our coils, as well as giving us the ability to design coils using methods that go beyond the capabilities of traditional machining.
It is common industry knowledge that the weakest parts of a coil are the braze joints, but through the R&D process, we have learned that by 3D printing the coils, it is possible to eliminate most, if not all, braze joints in the head of a coil. This increases the strength and, potentially, the life of a coil. After years of testing and evolving, the end results were better than we expected, proving that the coils can be printed and will last in the field.
However, there were some challenges in adapting to using 3D printing technology. For example, the type of copper printing we required was not being done in the United States, which was an obstacle in trying to form a process that resulted in a successfully printed coil. But one of the biggest challenges after we locked down the process and material was in designing the internal cooling passages for the coils. The passages needed to be designed in a way that was self-supporting and non-restricting. We had to produce the same flow rate as traditionally made coils and ensure we were driving the cooling into the right areas. Figuring that out took many failed attempts — learning opportunities — before achieving success.
Once that goal was achieved, we installed a metal 3D printer at Tucker Induction in January 2024 and have been successfully printing all different types of coils. Some examples include two turn ID, spindle, single-shot, and scanning coils.
The Benefits of Using 3D Printed Coils
While traditional coils (such as our interchangeable, quick-change coil for two-turn induction systems and single-shot designs with accurate clamping pressure) have changed the industry, the additional capability of 3D printing allows us to print dimensionally accurate, durable parts that are capable of performing in the field and that can go beyond the barriers of traditional machining.
3D printed coils bring several worthwhile benefits to the table including time savings, longevity, and faster coil repair. Time savings is one of the biggest advantages. Because the 3D printer can run “lights out,” the processing time from the printer to the client is far shorter when compared to traditionally fabricated coils. We refer to the processing time as the additional time needed to complete the coil assembly after printing. In some situations, it is possible to print a completed coil assembly with the coil immediately ready to be sent to the client. Other times, additional brazing or supplemental details may be required to complete the assembly.
Since all coils are different, the processing time varies from coil to coil. However, by printing as much of the assembly as we can, we are able to limit the amount of additional work needed to complete the job.
Strength and potential longevity of 3D printed coils are additional advantages. The weakest parts of the coil are the braze joints, but the process we use to print the coils drastically reduces the amount of braze joints, thus making the workforce of the coil a solid construction. This results in a product that will be stronger in the induction environment and has the potential to outlast its traditionally manufactured counterpart.
When it comes to the lifetime of the 3D printed coils, our baseline is that the printed coils need to last at least as long as traditionally manufactured coils. However, in our research, we have seen, on average, that our 3D printed coils can last two to three times longer than traditionally manufactured coils. While the longevity of each coil is case dependent, as there are many factors that go into the lifespan of a coil, one of our original test coils is still running in the field with over one million heat cycles.
While continuing to improve processes and designs, we are also pushing to decrease the time for repairs. Getting our clients’ coils repaired and returned in an effort to limit their downtime has always been something we strive for with our traditional coils, but we have found that 3D printed coils are easier to repair. Since multiple braze joints are not an issue in printed coils, it reduces the chance of causing additional problems as you work on the original repair. If the repair consists of replacing the head of the coil, we are able to recall the original print and run it again, as opposed to having to re-machine and re-assemble and braze the entire coil, significantly reducing the repair time of many 3D printed coils.
Limitations of 3D Printing Coils
Despite the advantages of 3D printing induction coils and the fact that the capability to print coils gets you into the mindset that every coil needs to be printed, there are some instances when it is still more effective to use traditional manufacturing.
For example, coils that are larger than the machine is capable of printing — our print bed size is roughly 12 x 12 x 13 inches — can be a limiting factor. Other times, the coil may be manufactured faster using traditional methods. The printer does have limitations, and it is not the best option for certain coils. For example, coils that are less intricate and made from tubing is one type that would be a better candidate for traditional manufacturing; these coils simply require wrapping copper tubing around a mandrel.
The Future of 3D Printed Coils
We are continuing to research and fine tune the processes of 3D printing our coils and strive to provide our clients with the best possible product. In order to do that, we must stay vigilant and be willing to continuously learn and improve our designs and processes.
As we learn more and perfect our 3D printing coil processes, I believe 3D printed coils will play a vital role in the future of the industry. We have proven that 3D printing coils is not just possible, but that in some cases 3D printed coils can outperform their traditionally manufactured counterparts.
About The Author:
Manager of Induction Heating
Tucker Induction Systems, Inc.
Josh Tucker graduated with a bachelor’s degree from Grand Valley State University and was then hired as the head of Purchasing at Tucker Induction Systems. Since starting eight years ago, Josh’s role and capabilities have expanded to machining, wire EDM, 3D printing, and laser engraving. He also organizes the day-today operations and flow of the shop floor. Josh was recognized in Heat Treat Today’s 40 Under 40 Class of 2024.
For more information: Contact Josh Tucker at JTucker@tuckerinductionsystems.com
