mechanical - How are air-core inductors typically constructed?

I'm considering learning to build air-core inductors for power applications.

For example, I presently want a .5-1 mH choke capable of handling 50 amps for two seconds. Winding my own air-core seems like it might be a cost-effective solution, but I'm not clear on how large coils like that would be physically constructed and held together.

I've used cable ties before, but that's a cheap and quick solution, not something I'd want to use for production, especially in any sort of high-vibration environment.

Is there a standard way such things are typically built?

Edit: these chokes are intended for use in ~600 VAC systems, so the insulation is going to have to have some pretty high withstand ratings.

Answer

It is as simple as using a form or armature over which you roll your wire. Once it's on the armature and wound up you can glue it together or even paint it with an epoxide paint that will give it strength. However, you will have to account for heat production. In some cases you might want to leave the coli on the the winding armature, if you've chosen the \$\mu_r\$ to be ~ =1 this could also be save.

If you are using litz wire you'll probably have to leave it on the armature.

There are companies that sell brackets and clips for this sort of thing. the term you will be looking for and here is a link to a page giving hardware. there are lots of competitors.