Radial Flux Motor Coil Manufacturing Solution
High-Precision Flat Wire Edgewise Winding for Next-Generation Electric Motors
Radial flux motors are widely used in electric vehicles, robotics, servo systems, industrial automation, and other high-performance applications. As motor efficiency and power density continue to increase, flat wire edgewise winding has become a preferred manufacturing technology due to its superior slot fill factor, thermal performance, and dimensional consistency.
This case study showcases Eurion’s customized manufacturing solution for precision radial flux motor stator coils, delivering stable quality from prototype development to mass production.
Project Background
Every motor design has unique winding requirements. In this project, the customer required a high-precision flat wire stator coil capable of maintaining consistent geometry while achieving a high slot fill factor and excellent production repeatability.
Key Requirements:
- Flat enameled copper wire
- High slot fill factor
- Tight bending radius
- Excellent dimensional consistency
- Automated production capability
Manufacturing Challenges
Producing radial flux motor coils requires much more than simply winding flat wire.
Major challenges include:
- Maintaining consistent turn spacing
- Preventing insulation damage during bending
- Controlling spring-back
- Ensuring repeatable coil geometry
- Supporting efficient mass production
Eurion Manufacturing Solution
To address these challenges, Eurion developed a customized flat wire edgewise winding process that combines precision servo control, dedicated forming tooling, and optimized winding strategies.
Key Features
✔ Precision servo wire feeding
✔ Flat wire edgewise winding
✔ Customized tooling design
✔ Stable multi-turn forming
✔ High repeatability
✔ Ready for mass production
Finished Coil
Unlike conventional individual coils that require bridge wire welding during stator assembly, Eurion’s integrated dual-coil design combines two adjacent coils into a single continuous winding. This reduces the number of inter-coil welding joints, simplifies assembly, improves electrical reliability, and shortens production time.
The finished stator coils feature smooth corner transitions, excellent dimensional consistency, and a high slot fill factor, making them ideal for automated motor assembly.
Typical Applications
- Electric Vehicles
- Robotics
- Servo Motors
- Industrial Motors
- Aerospace
- E-Bike Motors
Why Eurion
With years of experience in flat wire winding automation, Eurion provides complete manufacturing solutions for customized motor coils—from prototype validation to high-volume production.
From flat wire edgewise winding and precision coil forming to integrated stator assembly, Eurion provides a complete manufacturing solution for radial flux motor production. Every process is optimized to improve slot fill factor, reduce welding operations, and ensure consistent quality for prototype development and mass production.
