Post by Stanzwerk AG

Stranded round copper wire is becoming obsolete in high-performance EV traction motors. The industry standard is now hairpin winding. By utilizing flat, rigid, U-shaped solid copper bars, automotive engineers drastically increase the stator’s copper fill factor. This direct upgrade amplifies the magnetic field, generating significantly higher torque density while actively reducing the copper losses that limit vehicle range. However, hairpin stators demand flawless foundational geometry. Even minor inconsistencies in the lamination stack can disrupt automated hairpin insertion. Stanzwerk AG guarantees the precision required for advanced winding technologies. Our in-die stacking, welding and cleating techniques ensure that every stator core leaves our facility ready for seamless automated assembly. #HairpinStator #EVMotors #Engineering #TorqueDensity #ElectricMobility #Stanzwerk