Flexibility and Precision New Production Concepts for Electrical Steel Packages

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FAULHABER Drive Systems

Wuxi InfiMotion Technology Co., Ltd.

The manufacturing of stators and rotors is facing a fundamental paradigm shift. Traditional pressing technologies are increasingly reaching their technical, economic, and ecological limits. New approaches are needed that drastically reduce material usage, CO₂ emissions, and investment risks while putting flexibility and precision at the forefront.

The solution lies in modular manufacturing concepts and innovative processes such as automated segmentation, paving the way for sustainable electromobility production.

Limits of Classic Press Technologies

The production of stator and rotor laminations for electric motors has relied for decades on central, large stamping presses and large, complex stamping tools. However, the disadvantages of this approach are becoming increasingly apparent. "The enormous investment costs tie up capital for many years amid rising uncertainty about the actually needed capacities," explains Thomas Stäuble, CEO of SWD AG, a Swiss specialist in stator and rotor technology. Additionally, there is high material consumption, as the full-circle stamping process generates large amounts of high-quality electrical steel as scrap. Furthermore, the stator and rotor laminations are made from the same material in this process, which is often not sensible for the electric motor. The complexity of the geometries increases, requiring ever larger tools and presses. Weaknesses also appear in logistics: materials and lamination stacks must be transported in large quantities, leading to additional costs and significant CO₂ emissions.

In addition to the economic aspects, the ecological dimension is increasingly coming into focus. The high energy consumption of classic presses and the fragmented supply chains are becoming less compatible with the demands of sustainable production. "The traditional supply structure is too rigid, too resource-intensive, and too inflexible to meet the challenges of electromobility; instead, on-site production is needed," says Stäuble.

The Technological Leap: Decentralized Special Machine Concepts

Against this backdrop, a paradigm shift is inevitable. Decentralized manufacturing concepts offer the possibility to move production processes closer to actual demand—directly to the location of the OEM or engine manufacturer. "This not only shortens transportation routes and saves CO₂, but it also significantly reduces investment risk," emphasizes Stäuble. Instead of a central large press, OEMs can utilize smaller, modular facilities that can be expanded and/or duplicated as needed. This allows production capacities to be adjusted dynamically, making companies more resilient to market volatility.

A core component of these new approaches is automated segmentation, as applied by SWD, for example. This method replaces full-circle stamping with the production of individual segments that are subsequently assembled precisely. "This procedure drastically reduces material usage while simultaneously improving geometric precision," explains Stäuble. In pilot projects, SWD demonstrated that segmentation could save up to 27,000 tons of material and nearly 70,000 tons of CO₂ in large-scale production.

Material Usage and Energy Efficiency in Comparison

more material per stator-rotor pair, the demand in the segmented process is significantly lower, allowing for the possibility of using different materials for the stator and rotor. This effectively halves material usage, which has substantial positive effects on costs and sustainability. "Energy efficiency also improves: Fully automated, integrated systems for segments achieve OEE (Overall Equipment Effectiveness) values of up to 95 percent, while traditional presses often stagnate at 65 percent," adds Stäuble. The result is a significantly higher manufacturing efficiency.The modular machine concepts, such as those from SWD AG, are also designed to integrate seamlessly into existing production environments. They require less space than central presses and can be flexibly installed in existing facilities. "OEMs can start with one machine and later gradually duplicate it. This keeps investments manageable and allows production to grow in line with demand," explains Stäuble.In addition to material and energy efficiency, the new concepts score points for their high maintainability. The small and compact tools achieve a usage duration of up to 50 million strokes without needing re-sharpening. "This not only means lower operating costs but also significantly greater process reliability," emphasizes Stäuble. This is complemented by a high level of automation, which ensures stable quality and reduces the need for skilled labor.

Shift in Manufacturing and New Logistics Models

The relocation of manufacturing directly to the engine site changes the entire logistics approach. Instead of stamping and transporting tons of sheet metal packages centrally, processing occurs directly on-site. "This not only reduces the ecological footprint, but also increases the supply security for the OEMs," explains Stäuble. Dependency on global supply chains decreases, while responsiveness to market fluctuations increases.This new manufacturing technology offers further advantages: the small stamping tools are highly precise, and the influences of edge defects are reduced. Additionally, the material is not straightened, which leads to lower electromagnetic losses in the finished electric motor compared to traditional manufacturing. Thanks to segmentation and bonding technologies, lamination stacks can be produced with minimal tolerances. "All these factors reduce magnetic losses and significantly increase motor performance. This presents another crucial advantage for electromobility and aviation," says Stäuble.While the automotive industry currently has the greatest need, the application fields extend far beyond that. Industries such as aviation, energy generation, industrial drives, and household appliances can benefit from the advantages of modular and segmented manufacturing concepts. "Wherever electric drives are used, significant efficiency and sustainability gains can be achieved," adds Stäuble.

Operational Systems and Pilot Projects Demonstrate Market Readiness

Today, SWD AG has successfully implemented such machine concepts for its customers. The practicality of their approaches has been proven in various studies and pilot projects. In addition to material and CO₂ savings, the production processes have primarily been stabilized, and flexibility has increased. "This shows that we are on the right track and that our solutions are ready for mass production," explains Stäuble.

The future of stator and rotor manufacturing will be shaped by modular machine concepts. Automated segmentation will establish itself as the standard, not only in electromobility but also in other industries. The advantages are too significant to be ignored: substantial CO₂ reductions, flexible production capacities, lower costs, and higher precision.

The limitations of traditional press technologies make a technological leap unavoidable. Modular plant concepts and automated segmentation are paving the way for sustainable and economical production of electrical steel packages. OEMs are provided with solutions that combine investment security, flexibility, and ecological benefits. This opens a new chapter in the production of electric motors—one that benefits both the industry and the environment.

*Freelance Author