Solenoid & Bobbin Coils

Custom Solenoid & Bobbin Coils Made in the USA

General Linear Systems manufactures custom solenoid coils and bobbin coils for OEMs, engineers, and technical buyers who need electromagnetic components built around specific application requirements. From early design support to prototype, sample, and production quantities, GLS helps turn a print, concept, or performance target into a practical coil solution.

Our solenoid coils are used in actuation, switching, push-pull motion, solenoid valve operation, and other systems where space, force, heat, duty cycle, and fit all matter. With U.S.-made production and California manufacturing capabilities, GLS supports customers that need real-world engineering input and manufacturing flexibility.

Custom Solenoid Coil Manufacturing

A custom solenoid coil converts electrical energy into magnetic force. That force may move a plunger, open or close a valve, trigger a latch, control a locking mechanism, or support another actuator function.

GLS designs and manufactures custom solenoid coils tailored to each customer’s electrical, mechanical, and operating requirements, including voltage, resistance, wire gauge, pull force, duty cycle, operating temperature, insulation requirements, lead configuration, and available space.

Customers often come to GLS when an off-the-shelf coil does not fit the envelope, performance target, or sourcing requirement. GLS has experience manufacturing custom solenoids from approximately .150-inch O.D. to 5-inch O.D., depending on the application.

Solenoid Bobbins, Custom Coil Winding & Coil Assemblies

GLS offers access to more than 1,000 solenoid bobbin sizes, giving engineers flexibility when matching coil geometry, winding space, and assembly fit. Bobbin size, inside diameter, outside diameter, material, and available winding area can all affect performance.

Our custom coil winding capabilities support cylindrical coils, encapsulated coil assemblies, application-specific terminations, leads, connectors, insulation, and other assembly details.

In-house bobbin making capability and machine shop resources allow GLS to support design changes, fit requirements, and prototype-to-production development. Encapsulation may also be used when the coil needs added protection from vibration, moisture, handling, or demanding operating environments.

Applications & Industries

Custom solenoid coils are used anywhere controlled electromagnetic motion is needed. GLS supports commercial applications as well as OEM work in aerospace, defense, infrastructure, security, automation, transportation, medical, marine, hydraulic, air valve, and chip manufacturing-related systems.

Common applications include solenoid valve assemblies, switching solenoid coils, electromagnetic devices, push-pull actuators, locking and release mechanisms, hydraulic and air valve assemblies, control assemblies, and other magnetics or actuation components.

For technical buyers, the key question is not only whether the coil can be made. It is whether the coil can perform consistently in the real system. GLS helps customers think through fit, force, power draw, heat, duty cycle, production volume, and assembly method before the design moves too far downstream.

Design Details to Consider Before Requesting a Quote

A strong RFQ includes electrical and mechanical details such as voltage, current, target resistance, available space, bobbin dimensions, wire size, required force, stroke length, duty cycle, operating environment, lead or terminal requirements, quantity, and whether the request is for a prototype, sample, or production.

If a print, existing coil, or actuator sample is available, send it. If the design is still in its early stages, GLS can review the application and help identify the information needed to move forward.

A common sourcing mistake is treating the coil as a simple wound part instead of part of a complete electromagnetic system. Small changes in bobbin size, wire selection, winding pattern, heat buildup, or encapsulation can affect the finished solenoid's performance.

Why Choose General Linear Systems?

General Linear Systems combines coil design experience, in-house bobbin making capability, machine shop resources, and custom coil winding under one U.S.-based manufacturing partner. GLS supports custom solenoid needs from prototype and sample runs to recurring production quantities, with experience handling custom solenoids from 100 to 25,000 units per month.

Our computerized design support helps evaluate solenoid requirements early in the process, reducing guesswork around size, winding, electrical performance, and manufacturability. For engineers, that means a more informed design path. For sourcing teams, it means a clearer route from RFQ to production.

When you need custom solenoid coils, solenoid bobbins, coil assemblies, or related magnetics built around your application, GLS can help review your print, specifications, or project requirements.

Contact General Linear Systems today to request a quote or discuss your custom solenoid and bobbin coil needs.

FAQs

What is a custom solenoid coil?

A custom solenoid coil is an electromagnetic coil designed around a specific application rather than a standard catalog part. It typically creates magnetic force for actuation, push-pull motion, switching, or solenoid valve operation. Engineers may need a custom solenoid when the available space, voltage, force, duty cycle, environment, or connection style does not match an off-the-shelf option. GLS can review your print, sample, or design requirements to help determine the right coil approach.

What information is needed to request a custom coil quote?

To request a custom coil quote, provide as much electrical, mechanical, and application information as possible. Helpful details include voltage, resistance, current, duty cycle, bobbin dimensions (outside and inside diameters), wire size, pull force, stroke length, lead or terminal style, operating environment, and estimated quantity. A print, sample, or prototype target is also useful. If you do not yet have all the details, GLS can help identify what is needed.

Do you manufacture prototype and production quantities?

Yes, GLS supports prototype, sample, and production quantities for custom solenoid coils and coil assemblies. Early-stage projects may begin with a sample or prototype to confirm fit, force, and electrical performance before moving into larger production. GLS also supports recurring manufacturing needs, including custom solenoid quantities ranging from smaller runs to higher monthly volumes. This helps customers move from design validation to production with the same manufacturing partner.

Are your solenoid coils made in the USA?

Yes, GLS manufactures solenoid coils in the USA through its California manufacturing operation. U.S.-made production can help customers that need responsive communication, practical design support, and a domestic manufacturing source for custom coil winding, solenoid bobbins, and coil assemblies. For OEMs and technical buyers, domestic production can also simplify collaboration during design changes, prototype review, and production planning.

Can you build encapsulated or custom coil assemblies?

Yes, GLS can support encapsulated coil assemblies and other custom coil assemblies, depending on the application requirements. Encapsulation may help protect the coil from vibration, moisture, handling, or environmental exposure. Custom assemblies may also include specific bobbins, leads, connectors, terminations, insulation details, or fit requirements. The best starting point is to send a print, sample, or application description so GLS can review the assembly needs.

General Linear Systems, Inc.