Precision-Built Coils for Every Critical Winding
At Renown Electric, our coil manufacturing capabilities span every major motor and generator winding, including armature coils, stator coils, rotor pole coils, field coils, interpoles, and riser trays. We manufacture coils suitable for varnish and VPI treatments as well as resin-rich press cured (hard) coils. Our team designs, winds, insulates, and tests each coil in‑house to deliver reliable performance, long service life, and consistent quality in demanding industrial applications.
Whether you need a single replacement coil, a complete coil set for a large motor, or support for a complex rewind, our dedicated coil manufacturing shop provides fast, technically sound solutions.
Comprehensive Coil Manufacturing Capabilities
Our in‑house coil manufacturing facility is equipped to handle a wide range of coil types, sizes, and voltages, from small industrial machines to large, high‑horsepower motors and generators.
We manufacture:
- DC Armature coils for motors and generators
- Stator coils for form‑wound and random‑wound stators
- Rotor pole coils for salient pole synchronous machines
- Field coils for DC motors, generators, and exciters
- Interpoles (commutating poles)
- Riser trays for DC armatures and connection assemblies for organizing and insulating coil leads and risers
Each coil is built to your specifications or reverse‑engineered from existing equipment, using high‑quality copper conductors, insulation systems matched to your voltage and temperature class, and controlled winding and forming processes.
Armature coils are at the heart of many motor and generator designs, where they create the electromagnetic field that converts electrical energy into mechanical power. Our armature coil manufacturing services cover:
- Custom armature coil design and winding for new and legacy equipment
- Replacement armature coils for DC motors and large industrial generators
- Insulation systems tailored to your operating voltage, environment, and duty cycle
- Full testing of wound armature coils before installation or shipment
We support both straightforward armature rewinds and complex large‑motor armature rebuild projects, helping customers minimize downtime and extend equipment life.
To see how this applies in the real world, explore our work in the Westinghouse Armature Rebuild case study, where in‑house armature coil manufacturing played a key role.
Stator coils form the stationary winding system in many AC motors and generators, where precision and insulation quality are critical. Our stator coil manufacturing capabilities include:
- Form‑wound stator coils for medium‑ and high‑voltage machines
- Random‑wound stator coils for lower‑voltage and smaller motors
- Precision forming, bracing, and insulation techniques to ensure proper fit in stator slots
- Varnish and resin impregnation to enhance dielectric strength and mechanical stability
By producing stator coils in‑house, we can closely coordinate coil manufacturing with our motor rewinding and repair services to reduce turnaround times.
Many large motors and generators rely on specialized coils in their rotor and DC excitation systems. Renown Electric manufactures:
- Rotor pole coils for salient pole synchronous machines
- Field coils for DC motors, DC generators, and excitation systems
- Interpoles for DC machines to improve commutation and reduce sparking at the brushes
These coils are engineered to withstand mechanical forces, thermal cycling, and magnetic stresses in heavy‑duty service. We select conductor sizes, insulation systems, and coil support methods to match each application’s electrical and mechanical requirements.
Reliable connections are as important as the coils themselves. We design and manufacture:
- Riser trays to organize, support, and insulate coil risers and leads
- Connection assemblies that route coil leads to terminals, bus bars, or commutators
- Insulated supports and hardware to protect against vibration, tracking, and electrical stress
Integrating riser trays and connection assemblies into our coil manufacturing process helps ensure clean, serviceable, and robust terminations for your rebuilt or newly wound equipment.
Request an Coil Manufacturing Quote
If you need armature, stator, rotor pole, field, interpole coils, or riser trays, Renown Electric can help.
Our team will review your requirements and recommend the best coil manufacturing or replacement approach for your equipment.
In‑House Coil Manufacturing Capabilities
Our coil manufacturing facility in Concord, Ontario, is fully equipped to produce everything from small replacement coils to complete armature sets for high‑horsepower motors and generators.
Our custom coil manufacturing capabilities include:
- Custom coil design and copper winding for new builds and replacements
- AC and DC motor coil manufacturing for a wide range of voltages (up to 13.8 kV)
- High‑voltage insulation systems, slot liners, and precision coil insulation wrapping
- Green coils suitable for VPI treatment
- Resin-rich press cured (hard) coils, often referred to B-stage, that do not need treatment.
- Advanced testing, including strand to strand, turn to turn (surge), tap, resistance, impedance, insulation resistance and Hipot test
- Rapid turnaround on armature coil rewinding and replacement projects
Because we handle in‑house coil manufacturing and testing under one roof, you get tighter process control, shorter lead times, and more consistent quality than outsourced coil suppliers.
To learn more about our broader repair capabilities, visit our Electric Motor & Generator Repair services page.
Robotic Taping and Wrapping for Consistent Insulation
Renown Electric enhances traditional craftsmanship with robotic taping and wrapping automation as part of our industrial coil manufacturing process. This robotic system applies insulation tapes with exceptional accuracy and repeatability—critical for consistent coil integrity and long service life in high‑duty applications.
Benefits of our robotic coil insulation and taping systems include:
- Apply insulation tapes with consistent tension, overlap, and coverage
- Reduce manual variation and improve repeatability across coil sets
- Increase mechanical strength and heat resistance in critical coil areas
- Support faster, more efficient coil production without sacrificing quality
Our technicians program and monitor each robotic taping cycle to match your specifications and applicable OEM or EASA requirements. This combination of robotic taping and expert oversight is a key differentiator in our industrial armature coil manufacturing services.
You can see more about our equipment and processes by exploring our facilities and winding workshop.
Engineering Expertise and Quality Assurance
From material selection to final testing, every coil passes through a controlled, documented process:
- Engineering review of coil design, insulation class, and duty requirements
- Controlled winding, forming, and insulating procedures for each coil type
- Electrical testing, including resistance, insulation resistance, surge, and hipot tests where applicable
- Dimensional checks to verify proper fit in slots, on poles, or around cores
As an experienced, EASA‑approved motor repair and coil manufacturing partner, we apply the same stringent quality standards to coil manufacturing as we do to complete motor and generator rebuilds.
Industries and Applications
Renown Electric supports coil manufacturing needs across a wide range of industries and applications, including:
- Mining, steel, and heavy manufacturing facilities that depend on large industrial motors
- Transportation and rail systems that require dependable AC and DC motor armature coils
- Power generation and utilities needing reliable coil replacement for critical equipment
- OEM equipment manufacturers and repair shops seeking a long‑term coil manufacturing partner
Whether you need armature coils for a DC mill motor, stator coils for a medium‑voltage pump motor, rotor pole coils for a synchronous generator, or field coils for a DC machine, Renown Electric can manufacture and supply coils tailored to your application.
For on‑site support around large rotating equipment, you can also leverage our field and on‑site machining services.
Why Choose Renown Electric for Coil Manufacturing?
When you choose Renown Electric for armature coil manufacturing, you get:
- Over 40 years of hands‑on experience in coil manufacturing, rewinding, and motor repair
- A complete in‑house coil manufacturing shop with robotic taping and wrapping capabilities
- SKF certified and ISO‑ and EASA‑aligned processes focused on reliability, safety, and repeatability
- Proven success in large motor armature rebuild projects and legacy coil replacement
- Fast response times supported by stocked copper, insulation, and coil manufacturing materials
As a trusted electric motor specialist serving customers across North America, Renown Electric delivers custom coil manufacturing solutions that help keep your critical equipment online. Reliability isn’t a goal – it’s our commitment!To learn more about our wider service offering, visit our Electric Motor & Generator Services overview.
Coil Manufacturing FAQ
What is industrial coil manufacturing?
Industrial coil manufacturing covers the design, winding, insulation, and testing of copper coils used in electric motors, generators, and other electromagnetic systems. This includes armature coils, stator coils, rotor poll coils, DC field coils, interpoles, and riser trays. Each coil type plays a specific role in generating or transferring electromagnetic energy, and precision in manufacturing directly impacts machine performance, efficiency, and reliability.
Can you manufacture replacement coils for obsolete or legacy equipment?
Yes. Renown Electric manufactures replacement coils for legacy and obsolete motors, generators, and related electromagnetic assemblies. Using existing coil patterns, reverse-engineering from original components, or working from drawings and specifications, we can replicate or redesign coils to match your application. This allows operators to maintain critical equipment performance without depending on discontinued OEM parts.
Are all coils manufactured in-house?
Yes. All coil manufacturing—including armature, stator, rotor, field, and interpole coils—is completed in-house at our facility. Our processes include precision winding, robotic taping and wrapping, resin impregnation, curing, and electrical testing. Performing every step on-site gives us full control over quality, lead times, and customization options.
What information do you need to quote a coil manufacturing project?
To provide an accurate quote, we typically request the following:
- Motor or generator nameplate data
- Photos of the existing coils or assemblies
- Basic dimensional information (slot size, coil span, wire gauge, etc.)
- Any available drawings, samples, or engineering specifications
If you lack detailed information, our technical team can assist in measuring, documenting, or reverse-engineering your coils to begin production quickly and accurately.
Do you support both AC and DC coil manufacturing?
Yes. Renown Electric designs and manufactures coils for both AC and DC machines, including traction motors, industrial drives, alternators, and power generation systems. We can tailor coil geometry, conductor format, and insulation materials to meet your voltage, duty cycle, and environmental conditions (such as high temperature, vibration, or moisture exposure).
What types of coils can you manufacture?
We manufacture a full range of coils for rotating electrical machines and electromagnetic systems, including:
- Armature Coils: Core windings that convert electromagnetic energy into torque.
- Stator Coils: Stationary windings generating the magnetic field in AC machines.
- Rotor Pole Coils: For salient and cylindrical/round rotors.
- Field Coils: Used in DC motors and generators to produce a consistent magnetic field.
- Interpoles: Auxiliary coils positioned between main poles to reduce sparking and improve commutation.
- Riser Trays: Insulated copper connectors providing current transfer between coils and commutator segments.
Can you customize coil designs for unique applications?
Absolutely. Our engineering team can design custom coil configurations for specialized applications—whether you’re upgrading insulation systems, improving thermal performance, or adapting a legacy design for modern standards. Each coil is engineered and tested to meet your specific performance and dimensional requirements.
Types of Bearing Damage and Failures
Bearings are an essential component of electric motors. They provide shaft support, facilitate even load handling, reduce friction between the shaft and stationary parts of the motor, and increase the longevity and reliability of rotating assets.
Get in Touch with our Skilled Team
No matter your industry or application, we’re here for you. Contact us to learn more about our extensive capabilities, and how we serve clients across industries to ensure their motors are operating at their best.