Seamless Prototype Air Core Inductor Custom Air Coil Inductor 6G WiFi 7 Ready Volume Production
Custom Air Core Inductor Future Proof Next Gen 6G Wi-Fi 7 Ready Seamless Prototype Volume Production Scaling
HALA-CUSTOM-FP: Future-Proof Air Core Inductor for 6G/Wi-Fi 7 & Seamless Production Scaling
Future-Proofing for Next-Gen Telecom — 6G/Wi-Fi 7 Ready
The HALA-CUSTOM-FP is engineered for multi-generation telecom roadmaps. Air-core μ₀=1.0 physics is valid to optical frequencies — no Snoek's limit, no gyromagnetic resonance, no frequency-dependent permeability collapse that limits ferrite inductors above 2GHz. The platform covers 5G FR2 (24–47GHz) production-qualified, Wi-Fi 7 (5.9–7.1GHz, 320MHz BW) with flat L(f) for wideband channel matching, Wi-Fi 8/60GHz WiGig geometrically ready, and 6G sub-THz (110–300GHz) platform-ready with sub-100µm ID mandrels and single-turn geometries.
Seamless Scaling: Prototype to Volume Production
The transition from prototype to production is where most custom component programs fail. The HALA-CUSTOM-FP eliminates this discontinuity by keeping the manufacturing platform identical at every scale: same tungsten carbide mandrel, same closed-loop servo wire tension, same 100% in-line optical inspection, same per-coil RF test station. The coil measured from a 10-piece prototype lot is statistically indistinguishable — within VNA measurement uncertainty — from the coil measured from a 10,000-piece production lot six months later. Volume capacity scales to 100,000+ pieces per month via multi-machine parallel production.
100% RF Electrical Testing & Sorting at Any Scale
Every coil receives 100% RF testing (L, Q, SRF, R_DC) with per-coil 2D data matrix identification — identical test architecture from the first prototype to the millionth production coil. Production scaling amplifies quality problems; 100% testing eliminates them at source.
Key Specifications
| Parameter | Value |
|---|---|
| Frequency Coverage | 100 MHz – 20 GHz production, extendable to 300 GHz platform-ready |
| 5G FR2 Readiness | 24–47 GHz, production qualified |
| Wi-Fi 7 Readiness | 5.9–7.1 GHz, 320MHz BW, flat L(f) |
| 6G Sub-THz Readiness | 110–300 GHz, platform-ready |
| Prototype-to-Production Identity | Same mandrel, wire, tension, test — identical S-parameters |
| Volume Capacity | Up to 100,000+ pieces/month |
| RF Test Coverage | 100% per-coil: L, Q, SRF, R_DC — all volumes |
| Coil Inner Diameter | 0.3 mm – 5.0 mm, sub-0.3mm for sub-THz |
| Turn Count | 1–50 turns (single-turn for sub-THz) |
| Wire Diameter | 0.03, 0.05, 0.08, 0.10 mm enameled copper |
| Wire Material | OFHC Copper (99.9%), silver-plated or gold-bonded |
| Inductance Range | 2 nH – 500 nH (sub-nH for sub-THz) |
| Q Factor | ≥100 @ 1 GHz |
| SRF | >20 GHz (>50 GHz custom geometries) |
| Max Current | Up to 500 mA DC, zero magnetic saturation |
| Operating Temperature | -55°C to +125°C |
| Lead Configuration | Straight axial, SMD flat-top, custom |
| Lead Plating | Electroless tin, silver, gold flash, solder-dipped |
| Test Data | S2P Touchstone per lot (100MHz–26.5GHz, 201 points) |
| Compliance | RoHS, REACH, Halogen-Free, CM-Free |
| Platform | HALA precision automated winding |
| Prototype Lead Time | 5–7 business days, MOQ 10 pieces |
Applications
- 5G FR2 to 6G Migration Path — same platform, supplier, and air-core physics across generations
- Wi-Fi 7 Tri-Band Routers and Access Points — wideband flat inductance across 2.4/5/6GHz
- LEO Satellite Constellation User Terminals — seamless scaling from 10 to 10,000+ units
- mmWave Automotive ADAS Sensor Front-Ends — platform consistency for multi-year programs
Contact us with your current frequency band, future roadmap requirements, and production volume forecast. Prototype quantities with full scaling assessment ship in 5–7 business days.
Get in Touch
Have questions about our products or want to discuss a custom order? Our team is ready to help you.