Integration of Hairpin Forming, Stator Stamping, and Advanced Welding Solutions Enhances Production Efficiency and Quality for Next-Generation Electric Motors and EV Powertrains
AMADA WELD TECH, a leading manufacturer of welding, marking, cutting, sealing, and bonding equipment and systems, together with AMADA PRESS SYSTEM, is advancing electric motor manufacturing with an integrated approach that unites forming, stamping, and welding technologies. This combined capability has the potential to streamline production of next-generation electric motors, enabling manufacturers to improve efficiency, precision, and overall performance in high-volume environments such as electric vehicle (EV) motor assembly.
As electric motor design continues to evolve, manufacturers are turning to pre-formed rectangular copper conductors known as “hairpins,” instead of traditional round-wire windings. These conductors are inserted into the stator core, locked in place, and joined at their ends. AMADA PRESS SYSTEM’s ES-1A 48-axis coil processing machine combines feeding, straightening, peeling, cutting, bending, and pressing flat copper wire in a continuous process.
AMADA PRESS SYSTEM technologies are also making a significant impact in stator manufacturing. The company’s modular three-segment stator stamping approach replaces traditional single-piece stamping, improving material yield, reducing press size, and lowering total energy use. Compact, high-precision presses combined with automated feeders, like the SDEW-i3 GORIKI high-rigidity, high-speed precision series of presses and the ALFAS-03ARZ high-speed, high-precision NC roll feeder, enhance consistency while eliminating the need for large-scale infrastructure.
AMADA WELD TECH offers several technologies for welding the hairpin ends, including laser welding, micro TIG welding, and resistance brazing. Laser welding offers a non-contact method ideal for high-speed assembly and integrates seamlessly with vision systems for alignment and quality assurance. Micro TIG welders provide a flexible, cost-effective alternative for low-volume or maintenance operations, while resistance brazing ensures strong joints well-suited to more forgiving geometries.
AMADA WELD TECH and AMADA PRESS SYSTEM’s integrated technology ecosystem empowers manufacturers to improve quality control, streamline workflows, reduce operational costs, and accelerate the development of next-generation electric motors. This synergy is amplified by AMADA ONE, an initiative that brings together the expertise of AMADA WELD TECH and other AMADA Group companies. By offering unified solutions and innovative resources, AMADA ONE helps customers overcome every metalworking challenge and achieve greater efficiency and process synergy across fabrication, stamping, welding, and machining operations.
For more information, visit https://amadaweldtech.com/blog/electric-motors-blog/.