R&D / Prototyping
Mid-to-Small Hairpin Stator Prototyping & Custom Automation
We prototype and sample-test mid-to-small hairpin stators, co-developing new hairpin designs together with our customers. When a prototype proves out, we can custom-build the automation to produce it. We do not supply heavy automotive traction-motor lines at this stage.
Hairpin winding replaces round wire with formed rectangular conductors, packing the stator slot far more tightly for higher copper fill, efficiency and thermal performance. It is the direction motor design is moving — from e-bikes and scooters to small industrial and EV-class motors.
Our current focus is mid-to-small hairpin stator prototyping and sample testing. We work as a joint R&D and prototyping partner — developing and testing new hairpin designs together with customers, on the winding, insertion, fusing and test platform we have refined since 1992.
When a prototype succeeds, we have the engineering flexibility to scale it up and custom-build the automated equipment to produce it. To be clear about where we are today: we do not supply heavy automotive traction-motor lines at this stage — our strength is the prototyping, the sample testing, and the mid-to-small custom automation that follows a proven prototype.
How we work on hairpin
Prototyping & sample testing
Mid-to-small hairpin stator prototypes and sample runs, developed and tested against your slot geometry and conductor cross-section.
Joint R&D with customers
We co-develop and test new hairpin designs together as a prototyping partner — tuned to the real part, not adapted from a generic machine.
Custom automation, once it is proven
When a prototype proves out, we scale it into purpose-built automation for mid-to-small hairpin production.
Clear about scope
We do not supply heavy automotive traction-motor lines at this time. Our focus is mid-to-small hairpin prototyping and the custom automation that follows.
The hairpin stages we prototype
A hairpin stator flow typically runs these stages. We prototype and sample-test them against your part, then custom-build the automation your production needs.
- 1
Slot insulation
Insulation paper inserted into the stator slots.
- 2
Hairpin forming
Rectangular conductors formed into hairpin (U) shapes.
- 3
Insertion
Formed hairpins inserted into the stator slots.
- 4
Twisting
Conductor ends twisted and aligned for connection.
- 5
Welding / fusing
Conductor ends joined, with process data logged.
- 6
Test
Electrical test and end-of-line quality verification.
Related stator equipment we build
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