Novel methods of encapsulating coils using thermoplastics speed manufacturing and allow for multifunctional designs that eliminate parts and simplify assembly. The author reviews and reports on recent developments in materials, processing techniques, and applications in this area. With regard to applications. two new fields for thermoplastic encapsulation have opened up: automotive sensors and motor stators. Also, more and more solenoids and transformers are being encapsulated with thermoplastics. As for materials, nylon 6/12 and toughened PET extend the range of part design and processing possibilities. They are good complements to nylon 6,6 and standard grades of thermoplastic polyesters. Ongoing research and development in processing have expanded the knowledge of tooling designs and molding parameters that optimize product quality, extend the design horizon, and reduce the time and cost of developing new applications.
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