Layered wing coil for an electromagnetic dent remover

A method for making an electromagnetic coil assembly, comprising:

• forming a first helix and a second helix, each helix having a first end and a second end and a substantially oval cross-section, the cross-section having a major axis, each helix being configured to concentrate electromagnetic flux at a midpoint on the major axis;
• bending each helix at an angle along a line in the plane of the cross-section parallel to and offset from the major axis resulting in a first planar surface including the major axis and a second planar surface, each planar surface having an outer edge opposite the offset line;
• orienting the first and second helixes such that the outer edges of the respective second planar surfaces coincide and the outer edges of the respective first planar surfaces are in diametric opposition;
• affixing the first helix to the second helix by their respective second planar surfaces;
• and
• connecting electrically the second end of the first helix to the second end of the second helix.

A method of fabricating an electromagnetic coil assembly, comprising:

• forming first and second helixes, each helix having a first end and a second end and a cross-section having a major axis, and being angled along a line in the plane of the cross-section parallel to and offset from the major axis resulting in a first planar surface including the major axis and a second planar surface, each planar surface having an outer edge opposite the offset line;
• orienting the first and second helixes such that the outer edges of the respective second planar surfaces coincide and the outer edges of the respective first planar surfaces are in diametric opposition;
• affixing the first helix to the second helix by their respective second planar surfaces;
• and
• connecting electrically the second end of the first helix to the second end of the second helix, wherein the first and second helixes are configured to concentrate electromagnetic flux at a midpoint on the major axis.