The modular coils for the National Compact Stellarator Experiment (NCSX) presented a number of significant engineering and manufacturing challenges due to their complex shapes, requirements for high dimensional accuracy and the high current density required in the modular coils due to space constraints. Some of these challenges included developing techniques to manufacture highly shaped coils which utilize copper rope conductor, dimensional control, and Vacuum Pressure Impregnation [VPI] operations. Production style manufacturing operations were introduced in order to maintain schedule and contain costs. This paper will discuss those challenges and manufacturing steps that were taken to successfully manufacture the Modular Coils. A general description of the tooling and equipment necessary to manufacture the modular coils will also be presented.
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