What Is The Difference Between Wirewound And Molded Inductors?

When it comes to choosing the right type of inductor for your design, understanding the differences between various types of inductors is crucial. Two commonly used types in the electronics industry are wirewound and molded inductors. The choice between them can significantly affect the performance and efficiency of your device. In this blog, we’ll break down the key differences, explore their respective advantages, and help you decide which inductor suits your needs best.

At SGTE Inductor, we understand the importance of making informed choices when it comes to inductor selection. As a leading professional inductor manufacturer, we offer high-quality molded inductors, among other types, tailored to meet the needs of various industries including automotive electronics, aerospace, and healthcare. Let’s dive into the specifics of wirewound and molded inductors.

What are Wirewound Inductors, and How Are They Made?

Wirewound inductors are one of the oldest and most commonly used types of inductors in the market. They are made by winding wire, typically copper, around a core. This process creates a coil that exhibits inductance due to the magnetic field generated when electrical current flows through the wire.

Construction Method
The construction of wirewound inductors involves winding a conductive wire around a central core, which can be made of materials such as ferrite or iron. The wire is usually coated with an insulating layer to prevent short circuits. This coil is then encapsulated with a layer of resin or plastic to protect the inductor from external damage.

Typical Characteristics and Applications
Wirewound inductors are typically known for their high inductance values and excellent current handling capabilities. They are widely used in power supplies, radio frequency (RF) circuits, audio equipment, and filtering applications. Their ability to handle higher currents and produce larger magnetic fields makes them ideal for low-frequency applications.

Advantages in Specific Environments
Wirewound inductors excel in applications where high inductance and power handling are crucial. Their efficiency in energy storage and magnetic field generation makes them suitable for power supplies and automotive electronics. However, they are generally bulkier and may not be as efficient in terms of size for high-frequency applications, where other inductors like molded types might be better suited.

How Are Molded Inductors Constructed Differently?

Molded inductors, as the name suggests, are inductors that are molded into a compact shape, usually encased in a resin or plastic material. Unlike wirewound inductors, molded inductors do not involve wrapping the wire around a core but rather incorporate a core material directly within the molded structure, simplifying the manufacturing process.

Manufacturing Process Comparison
Molded inductors are made by placing the wire and magnetic core into a mold and then filling the mold with resin. The resin solidifies, forming a durable and compact inductor. The main difference in construction is that the molded process encapsulates the inductor in a protective layer of resin that offers mechanical support and protection against environmental stressors.

Impact on Size, EMI, and Mechanical Strength
Molded inductors have a significant advantage in terms of size. Their compact and durable design allows for space-saving in tight applications. Additionally, the resin casing helps reduce electromagnetic interference (EMI), making molded inductors ideal for noise-sensitive applications. Molded inductors also exhibit higher mechanical strength due to their solid construction, making them more resistant to vibrations, shocks, and other mechanical stresses.

What Are the Performance Differences Between the Two?

When comparing wirewound and molded inductors, there are several key performance factors to consider. Both types have their strengths, but understanding their differences will help in choosing the right one for your application.

Electrical Efficiency and Thermal Performance
Wirewound inductors typically offer higher electrical efficiency because they can handle higher currents with less resistance. However, this comes with the challenge of heat generation, particularly in higher power applications. Molded inductors, on the other hand, are designed to dissipate heat more effectively due to their compact form and protective resin casing, which helps manage thermal performance better than wirewound inductors in certain environments.

EMI Suppression and Noise Management
Molded inductors are superior in terms of electromagnetic interference (EMI) suppression and noise management. Their resin coating provides a barrier that minimizes the leakage of electromagnetic energy, making them more suitable for noise-sensitive applications. While wirewound inductors are good at filtering low-frequency noise, molded inductors are often a better choice for higher-frequency noise suppression, which is common in modern electronic devices.

Cost vs. Value Considerations
When considering the cost, wirewound inductors tend to be more affordable for low-frequency applications due to their simpler manufacturing process. However, for applications requiring high mechanical strength, EMI suppression, or compact size, molded inductors provide better value despite their slightly higher cost. In high-volume or specialized applications, the benefits of molded inductors often outweigh the initial cost difference.

Which One Should You Choose for Your Application?

Now that we’ve examined the key differences between wirewound and molded inductors, how do you decide which one is best for your project? The choice depends on a variety of factors, such as the size constraints, power requirements, reliability needs, and budget for your application.

Side-by-Side Use Case Analysis

Wirewound Inductors: These inductors are best suited for applications where high current handling and inductance are critical. They are often used in power supplies, audio systems, and filtering circuits, where size is less of an issue, and the application operates at low frequencies.

Molded Inductors: Molded inductors are ideal for compact and noise-sensitive applications. If you are designing high-frequency circuits, automotive electronics, or space-constrained devices, molded inductors are likely the better choice due to their compact size, mechanical strength, and EMI suppression capabilities.

Design Criteria

Size: If your design requires a compact solution, molded inductors offer a space-saving advantage.

Power: For high-power applications, wirewound inductors generally outperform molded inductors in terms of current handling.

Reliability: Molded inductors excel in reliability, especially in rugged environments where mechanical stress and vibration are concerns.

Cost: Wirewound inductors may be more cost-effective for low-power and low-frequency applications, but molded inductors can provide greater long-term value for high-frequency and compact designs.

Expert Suggestions for Engineers and Buyers
At SGTE, we recommend molded inductors for most modern applications that require a balance between size, noise suppression, and mechanical durability. For automotive electronics, RF circuits, and miniaturized devices, molded inductors are often the best choice. However, for high-power, low-frequency applications, wirewound inductors may still be the go-to solution.

Conclusion

Choosing between molded and wirewound inductors depends entirely on your application’s specific needs. If size, EMI suppression, and mechanical strength are your priorities, molded inductors will likely be the ideal solution. However, if power handling and inductance are critical, wirewound inductors may be more appropriate.

At SGTE, we offer a wide range of high-quality molded inductors that are perfect for applications in automotive, aerospace, and other industries. Our products are built to meet the highest standards of performance and reliability, ensuring that your design succeeds.

Contact Us
If you're still unsure which type of inductor best suits your needs or if you require customized recommendations, feel free to reach out to SGTE. Our team of experts is here to help you find the perfect solution for your application. Contact us today to discuss your requirements and get the best inductor for your project!