The Importance of Thermo-Compression Bonding Technology

The demand for micro-coils is increasing to manufacture several miniaturized and microscopic parts for modern medical and electronics applications such as sensors and transducers. However, building these components requires the joining of ultra-fine wires. Although there are some traditional methods for joining two ultra-fine wires, these methods are not effective to overcome several manufacturing challenges. For this reason, modern manufacturers have developed a significant technique to connect two different ultra-fine wires, and this technique is known as Thermo-Compression Bonding Technology. This process does not only help to connect two ultra-fine wires of similar material and diameter but is also effective to link up two different ultra-fine wires, even if a wire is made of different metal and twelve times thicker than the other wire.

The ultra-fine wires are also useful in several applications, for instance, to wind coil for the manufacturing of state-of-the-art micro-motion positioning and control systems. To join the ultra-fine wires, there are two traditional methods such as soldering method (through applying another metal of low melting point) and the welding method (through melting the wires together). Due to the lack of effectiveness of these methods, the emergence of Thermo-Compression Bonding technology has replaced the traditional methods. With the help of the thermal compression process, you can very easily connect ultra-fine wires of 9 microns in diameter. Therefore, in comparison to human hair, the ultra-fine wire can be 5-10 times smaller. On the other hand, traditional methods do not have the ability to handle several environmental and physical challenges. Above all, the traditional methods can’t fulfill the ultra-strict tolerance requirements of the components.

Connections Through Thermo-Compression Bonding Technology

Thermo-compression bonding technology is effective in connecting:

  • Different ultra-fine wires using copper thermocouples
  • Two micro-coils of different metals using intermediate wires in the printed circuit boards
  • Micro-coils with a support system through metal-plated terminals


There are several advantages for using thermo-compression bonding technology:

  • This technology helps to decrease the noise level
  • You can have strain-free, corrosion-free, and highly reliable connections with the help of this technology
  • To protect sensitive components, this technique follows safer procedures
  • The integration into mass production helps to reduce the costs of production
  • Automated manufacturing process helps to remove human errors


Thermo-compression bonding technology is essential for the manufacturing of micro-coils and to connect ultra-fine wires. Micro-coils and ultra-fine wire technology have several significant applications:

  • For the preparation of pain management devices and to manufacture the components of deep brain stimulation
  • For controlling and monitoring implanted pacemakers
  • To prepare the devices of electricity-based extirpations in therapeutic applications and in the case of electrophysiology treatments
  • To prepare orientation and navigation sensors for conducting several activities such as targeted drug delivery, stent positioning, implanted markers, targeted radiation catheters, highly accurate ablations, and endoscopic manipulation
  • For the manufacturing of pulsed electromagnets in dental and orthopedic treatments
  • To conduct wireless communication in the diagnostic sector with the help of miniature sensor implants.

Due to the above-stated applications, the utility of the thermo-compression bonding technology is increasing day by day.