Direct answer: Custom solenoid engineering companies — such as Wisconsin-based Solenoid Systems, which designs linear, latching, proportional and rotary solenoids plus hydraulic, pneumatic and water solenoid valves for aerospace, medical, automotive, off-highway and industrial customers — concentrate their in-house expertise on electromagnetic design, coil winding, resistance welding, overmolding and assembly. The stamped, deep drawn and machined metal around the coil and the valve is Balford's scope: deep drawn solenoid valve housings, magnetic sleeves, stop tubes, plunger guide tubes, C-frames, end caps, valve components, mounting brackets and manifolds, manufactured from controlled magnetic materials with in-house magnetic annealing, tight concentricity and automotive-grade documentation.
Why we are spotlighting Solenoid Systems
Solenoid Systems is a U.S.-based custom solenoid and solenoid valve developer whose published work includes positioning satellite instrumentation in space, water management systems, exhaust gas recirculation, cryogenic gas flow control and advanced medical procedures. Balford publicly lists Solenoid System Inc. among the solenoid valve and electromagnetic device manufacturers it works with on its solenoid valves industry page, next to partners in Europe, the US and China. This article explains what a company like Solenoid Systems focuses on internally, and where a metal fabrication factory like Balford fits in the same supply chain.
What Solenoid Systems publishes about itself
| Attribute | Public detail (solenoidsystems.com) |
|---|---|
| Company | Solenoid Systems |
| Location | 252 Enterprise Rd, Delafield, Wisconsin, USA |
| Position | Custom solenoids, solenoid valves and solenoid systems; engineering, design & development and manufacturing |
| Core manufacturing | Coil winding, resistance welding, overmolding and assembly; U.S.-based low-to-high volume production |
| Engineering tools | Electromagnetic FEA, CFD, dynamic simulation and a virtual development platform |
| Product range | Custom solenoids; hydraulic, pneumatic and water solenoid valves; proportional solenoid control; smart solenoids with embedded electronics |
| Industries served | Aerospace, medical, automotive, off-highway, industrial and water management |
| Stated applications | Satellite instrumentation positioning, EGR, cryogenic gas, water management and advanced medical procedures |
The descriptions above reflect what Solenoid Systems publishes about itself and are used only to show where external metal-part manufacturing fits inside a custom solenoid program.
Where Balford fits: the metal parts around a custom solenoid program
Solenoid Systems positions itself as an extension of its customers' development teams, taking a valve from concept to prototype to production. In that model, some metal parts are best made by a specialized stamping, deep drawing and machining factory:
| Public application area | Typical metal scope Balford manufactures |
|---|---|
| Water management solenoid valves | Valve housings, machined bodies and manifolds, seat retainers, coil shells and corrosion-resistant stainless or brass fittings |
| EGR / automotive exhaust gas recirculation | High-temperature housings and flanges, magnetic frames and armature guide tubes, heat-resistant stainless parts with IMDS and PPAP documentation |
| Cryogenic gas valves | Precision machined valve bodies, stem guides, flanges and thin-wall tubes with tight surface and cleanliness control |
| Off-highway and industrial solenoid systems | Progressive die stamped frames, yokes, brackets, hydraulic body components and manifolds |
Each row describes the kind of metal manufacturing Balford performs for solenoid and valve developers; it is not a claim about a specific Solenoid Systems program.
Anatomy of a custom solenoid: which metal parts go where
When engineers at a custom solenoid company design a new actuator or valve, the metal part list usually looks like this:
| Zone of the solenoid or valve | Metal part | Typical Balford process |
|---|---|---|
| Magnetic return path around the coil | C-frame, box-frame or deep drawn shell | Progressive die stamping, bending, deep drawing |
| Center of the coil | Stop tube / plunger guide tube / armature tube | Deep drawing or tube forming, magnetic annealing |
| Plunger / armature path | Magnetic sleeves, guide bushings, non-magnetic inserts | Precision deep drawing, CNC turning, fine blanking |
| Coil containment | Flanged coil shell, can, cover | Deep draw metal stamping |
| End construction | End caps, flanges, terminal plates | Stamping, fine blanking, CNC machining |
| Valve function | Valve body, seat ring, retainers, ports | CNC machining, deep drawing, assembly |
| Mounting & integration | Brackets, yokes, mounting plates, manifolds | Progressive stamping, CNC, assembly & subassembly |
| Terminals & connectors | Terminal tabs, connector shells, grommet plates | Precision stamping, selective plating |
The recurring engineering point: most of these parts participate in the magnetic circuit, the sealing path or both. They are functional components, not decorative covers.
Material science: the housing is part of the magnetic circuit
For a custom solenoid developer like Solenoid Systems, every metal part around the coil changes the force curve, response time, duty cycle and operating temperature range. Materials Balford selects, forms and documents include:
- Electrical pure iron (DT4C / DT4E-class) for soft-magnetic housings and stop tubes where high permeability and low coercivity define pull force.
- Low-carbon magnetic steel (1008 / 1010 / SPCC / DC01) for C-frames, yokes, sleeves and shields.
- Ferritic stainless (430F / 430FR-class) where corrosion resistance and magnetic function must coexist — common in water, EGR and fuel-handling valves.
- Austenitic stainless (304 / 316) for non-magnetic guide tubes, medical-adjacent and cryogenic components.
- Aluminum and brass/copper for non-magnetic windows, heat dissipation, fittings and terminals.
- Free-cutting steels and specialty alloys for machined armatures and bodies where specified.
After forming, Balford can apply controlled magnetic annealing to restore permeability in deep drawn shells and tubes — process window and atmosphere matter, which is why annealing is done in-house rather than treated as an afterthought. For sealed or precision valves we also perform deburring, passivation, electropolishing and cleanliness-controlled finishing so housings and bodies arrive ready for O-rings, welding or overmolding.
DFM checklist for a solenoid or valve program
When Solenoid Systems' engineers — or any custom solenoid builder — send us a drawing, the DFM review covers the points that decide whether the valve will hit its specification in production:
- Wall-thickness control in deep drawn parts — uneven walls change the magnetic path and the pull-in force.
- Concentricity between tube and flange — runout makes the plunger bind or creates an inconsistent air gap.
- Flatness and perpendicularity of flanges and end plates — the bobbin, frame and end plate must stack straight for consistent winding and stroke.
- Burr control on every cut edge — burrs cut magnet wire insulation or damage seals in assembly.
- Sealing-surface quality — for valve bodies, seats and retainers we hold flatness, finish and cleanliness for O-ring and diaphragm sealing.
- Magnetic annealing requirements — permeability targets need a defined process window, not an unspecified softening operation.
- Material certification and traceability — automotive and aerospace programs need lot traceability, IMDS, RoHS/REACH declarations and FAI/PPAP-level reports.
- Cleanliness and packaging - parts are cleaned, bagged and protected to the level agreed on the drawing.
One factory, four process families
Custom solenoid programs typically combine dozens of metal parts with different volumes and tolerances. Balford covers the range under one roof:
- Deep draw metal stamping — seamless shells, stop tubes, sleeves and cans, single- or multi-stage with ironing control for thin walls.
- Progressive die and precision stamping — high-volume C-frames, yokes, brackets, terminals, washers and fine-blanked sealing faces.
- CNC machining — turning, milling and wire EDM for valve bodies, complex flanges, prototypes and low-volume components.
- Sheet metal, tube and assembly work — frames, covers, manifolds and subassemblies ready for the customer's winding line.
The result is a shorter supplier list and a single DFM conversation for the whole metal scope of a valve program — from the shell around the coil to the body that meters the fluid. Related solenoid valve work can be seen in the case library and across our material selection pages.
Why solenoid engineering companies work with Balford
- They design the electromagnet; we make what holds it together — no conflict with their coil-winding and assembly floor.
- Magnetic material know-how — electrical iron sourcing, magnetic annealing and permeability testing under one roof.
- Automotive-grade documentation — ISO 9001:2015 quality system, FAI reports, PPAP support and IMDS, RoHS and REACH data.
- One factory, four process families — stamping, deep drawing, machining and assembly, so parts arrive consistent and coordinated.
- Fast engineering loop — send a PDF, DXF, STEP or IGES; we return a DFM review, material recommendation and quote, usually within one business day.
- Language and time-zone bridge — engineering support in English, German, Japanese and Chinese, backed by a 12,000 m² facility and capacity for low to high volume.
Frequently Asked Questions
Is Balford a manufacturing partner for custom solenoid companies such as Solenoid Systems?
Yes. Balford works with U.S.-based custom solenoid and valve developers such as Solenoid System Inc. as a metal-parts partner, manufacturing deep drawn housings, magnetic sleeves, stop tubes, frames, machined bodies and related components. Solenoid System Inc. is also listed among the partners on Balford's solenoid valves industry page. Specific program details are confidential between each customer and Balford.
Does Balford wind coils or build complete solenoids?
No. Balford is a metal manufacturer, not a coil winder. Coil winding, welding, overmolding and final solenoid assembly are done by solenoid engineering customers such as Solenoid Systems; we supply the precision metal parts that make those processes repeatable.
What metal parts does a custom solenoid builder usually source externally?
The parts that need dedicated tooling and magnetic control: deep drawn housings and cans, stop tubes and plunger guides, C-frames and yokes, end caps, valve bodies and manifolds, brackets and terminal components.
Which materials do you recommend when the housing is part of the magnetic circuit?
Electrical pure iron or low-carbon magnetic steel for the soft-magnetic path, ferritic stainless such as 430F/430FR where corrosion and magnetism must coexist, and aluminum, brass or austenitic stainless for non-magnetic components.
Can Balford meet automotive documentation for EGR and water valve programs?
Yes. Balford works to ISO 9001:2015, provides FAI reports, and supports PPAP with IMDS, RoHS and REACH declarations for stamped, deep drawn and machined metal components.
What is the fastest way to get a DFM review and quote?
Send the drawing with material, tolerance and annual quantity via rfq.balford.net or email shawn@balford.net. Include the coil outside diameter, target wall thickness or sealing details if you know them — we typically answer within one business day.