Fraunhofer IWU – Electric Coil
Streamlined Coil Production that Unleashes Motor Efficiency
Modern electric motors are growing increasingly sophisticated—and resource-intensive, to meet today’s performance and sustainability demands. The Fraunhofer IWU, led by Mirko Bach, has pioneered a groundbreaking method for manufacturing motor coils with optimal fit in trapezoidal stator slots. By shaping each coil winding to match its slot position, this forming‑based technique significantly boosts the slot fill factor from ~50% to over 80%. The result? More copper packed into each motor, reducing electrical resistance and increasing efficiency.
A forming process chain including local pressing, bending, and coil‑head calibration, creates trapezoidal copper‑ETP windings without wasted material. This resource‑efficient process consumes less energy than additive methods, uses simple tools, and supports high‑volume production. A structural proof‑of‑concept has demonstrated substantial technical viability.
© Fraunhofer IWU
Why is it important?
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Resource-saving & eco‑friendly: Higher copper utilization means less material waste. The forming method avoids additive‑manufacturing energy intensity, enabling greener production with simple tooling.
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Cross-industry impact: This innovation supports key sectors—automotive, aerospace, manufacturing—helping electrified systems become smaller, more efficient, and more sustainable.
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