Axial flux motor: Leading the way in new production technologies for lamination stacks
The axial flux motor is an important motor concept for the future. This is characterized by a high power density and low weight. New production processes are needed – for both wound and segmented lamination stacks. We are already ramping up series manufacturing of lamination stacks and have developed completely new manufacturing processes.
Production of axial flux motors suitable for series manufacturing
With the axial fluxmotor, the magnetic field does not flow radially, but axially. This places new demands on the lamination stack. Stators and rotors wound from electrical sheet or individual segments are typical components for the axial flux motor. Together with our expertise in materials, tools, machines, and processes, we can manufacture your axial flux motors on an industrial scale.
We are experts in the following technologies
- Wound and bonded stators/rotors with machining of the grooves
- Wound and welded stators/rotors with punched grooves
- Stator segments in 3D and pyramid shape punched and bonded, with each lamination having a different dimension
- Made from KO/GO material to reinforce the magnetic field
Future prospects with axial flux motors
We are already ramping up series manufacturing of lamination stacks and have developed completely new manufacturing processes. In collaboration with bonding varnish (Backlack) manufacturers, we are pursuing new combinations of materials and production processes. This opens up completely new possibilities.
Success stories
FAQ about axial flux motors
SWD’s proprietary winding and bonding technology enables the production of wound and bonded axial flux stator and rotor discs with exceptional mechanical strength and dimensional accuracy.
Thanks to their outstanding rigidity, these components can be subjected to precision machining processes – such as grinding, drilling, or milling – without compromising functionality or dimensional tolerances.
The high design flexibility of this winding technology also makes it ideal for complex geometries often required in advanced axial flux motors.
Additionally, a targeted post-treatment process ensures that potential short circuits caused by machining are reliably eliminated.
Functional features such as holes, threads, or couplings can be easily integrated, and even direct winding onto hubs has been successfully implemented. This results in complex, highly functional assemblies that are both easy to mount and efficient to manufacture.
The pyramid-shaped pole bars used in axial flux motors (AFM) are manufactured using a specially developed tooling concept based on our proven BPS® technology platform – a process ideally suited for the precise production of segmented electrical steel components.
Over the past five years, we have systematically refined this method, optimizing it for repeatability, material efficiency, and process stability.
We are currently building three fully automated production lines for large series manufacture of precision pole bars, fully prepared for integration into next-generation axial flux motor applications.
Yes – SWD is currently preparing large-series production of individual segments for axial flux motors (AFM), using advanced materials such as grain-oriented electrical steel (GO).
To enable this, several fully automated production systems are being installed – specifically designed to meet the high-precision demands of stator and rotor segment manufacturing for axial flux motors.
Over the past few years, numerous proprietary technologies have been successfully industrialized, with a strong focus on material efficiency, dimensional accuracy, and process reliability.
This makes SWD a reliable partner for OEMs and Tier-1 suppliers looking to realize high-performance AFM solutions in large-scale series production.
Impressions
Our specialist will be happy to answer any questions you may have.
Fact box
- High power density with low weight
- Winding and bonding for axial flux motors is available as standard
- Winding and welding for axial flux motors is available as standard
- We also process KO/GO material in series
- We produce 3D punched stator segments in series