Custom axial flux motor core and SMC stator manufacturing support for 3D flux paths, RFQ datasheet ranges, insulation coating, and prototype validation.
Use these ranges as an RFQ planning envelope. Final manufacturability, tolerances, density, and loss targets are confirmed after CAD, material grade, compaction direction, and validation method review.
| Parameter | RFQ Planning Range | Engineering Note |
|---|---|---|
| Supported core shapes | One-piece circular ring or disc, sector/fan-shaped segment, individual tooth, segmented stator, or optimized 3D flux feature | Shape selection should be reviewed against motor topology, press direction, demolding, winding access, and air-gap datum requirements. |
| Outer diameter review window | 30-800 mm | Applies to ring and disc-style axial flux core concepts before part-specific tooling review. |
| Inner diameter planning minimum | 25 mm min. | Lower limits depend on ejection, wall thickness, datum access, and assembly clearance. |
| Axial thickness window | 5-110 mm | Tall features require compaction and green-strength review before tool freeze. |
| Slot / pole feature count | 3-112 slots or tooth features | Pitch, tooth width, corner radius, and demolding direction drive the practical limit. |
| 3D tooth / yoke feature review | Drawing-dependent tooth height, tooth width, draft, fillet radius, slot access, and ejection clearance | Optimized 3D features must be screened for local density, edge chipping, green strength, winding clearance, and inspection access. |
| Material route | Insulated iron-powder SMC grade, buyer-selected or performance-selected | Grade selection should be tied to frequency, flux density, temperature, density, and loss target. |
| Density planning target | 7.4-7.6 g/cm3 target where geometry, SMC grade, and compaction route allow | Treat density as a sample-specific target to verify with part weight, measurement method, and local feature review. |
| Winding-ready insulation coating | Resin insulation coating before winding, coating area map, thickness window, visual check, and optional Hi-pot scope | Coating and insulation acceptance should be separated from magnetic loss acceptance because slot clearance and thermal path may change. |
| Mechanical bonding / curing scope | Adhesive bonding, resin bonding, post-press curing or stress-relief route, segment fixture, and carrier integration boundary | Bonding or curing should be defined as part of the supplied core scope only when the buyer drawing and assembly process require it. |
| Inspection and release package | FAI, CMM or 3D scan, CTQ dimensions, density check, magnetic report, coating or Hi-pot note, traceability, and packing record | Engineering, sourcing, and supplier quality should agree which records are needed before sample release. |
Evidence Pack
For custom product RFQs, the useful proof is a controlled evidence package: drawings, material route, inspection records, validation scope, and sample acceptance notes.
Evidence to Prepare
Shape family, OD/ID/thickness/slot count, STEP file, 2D drawing, datum plan, CTQ list, revision ID, and DFM risk notes.
Acceptance Focus
Prevents buyers from treating a broad 30-800 mm planning range as a guaranteed tooling decision.
Evidence to Prepare
SMC grade, density target, B-H or core-loss requirement, frequency, flux density, temperature, waveform, and magnetic test method.
Acceptance Focus
Helps R&D compare material and geometry options using the same condition the motor program actually needs.
Evidence to Prepare
Coating area map, coating thickness expectation, Hi-pot scope when required, adhesive or curing boundary, visual criteria, and slot-clearance notes.
Acceptance Focus
Reduces late failures where a magnetic core sample fits the datasheet but no longer fits the winding or assembly process.
Evidence to Prepare
FAI report, CMM or 3D scan, CTQ table, density result, magnetic or insulation report if scoped, traceability, and export packing record.
Acceptance Focus
Turns prototype cores into decision-ready records for sample approval, pilot sourcing, and repeat-order control.
| Buyer Checkpoint | Evidence to Prepare | Acceptance Focus |
|---|---|---|
| Can the public datasheet envelope be connected to the buyer-controlled CAD shape before quotation? | Shape family, OD/ID/thickness/slot count, STEP file, 2D drawing, datum plan, CTQ list, revision ID, and DFM risk notes. | Prevents buyers from treating a broad 30-800 mm planning range as a guaranteed tooling decision. |
| Can the material route and validation target be tied to the actual axial flux operating point? | SMC grade, density target, B-H or core-loss requirement, frequency, flux density, temperature, waveform, and magnetic test method. | Helps R&D compare material and geometry options using the same condition the motor program actually needs. |
| Can winding-ready insulation, resin coating, and bonding or curing scope be audited before samples ship? | Coating area map, coating thickness expectation, Hi-pot scope when required, adhesive or curing boundary, visual criteria, and slot-clearance notes. | Reduces late failures where a magnetic core sample fits the datasheet but no longer fits the winding or assembly process. |
| Can engineering, sourcing, and quality review the same release package? | FAI report, CMM or 3D scan, CTQ table, density result, magnetic or insulation report if scoped, traceability, and export packing record. | Turns prototype cores into decision-ready records for sample approval, pilot sourcing, and repeat-order control. |
Any released claim should be tied to the buyer drawing, sample ID, material batch, inspection method, and agreed test condition instead of a generic marketing statement.
| Metric | Typical Range | Why It Matters |
|---|---|---|
| Custom geometry envelope | Circular, sector/fan-shaped, segmented, and optimized 3D tooth concepts within RFQ-reviewed OD 30-800 mm planning window | Axial flux programs often need shapes that do not map cleanly to conventional radial-motor lamination tooling. |
| Flux path suitability | 3D isotropic SMC geometry | Axial flux machines use magnetic paths that are not naturally aligned with stacked silicon steel laminations. |
| Density planning | 7.4-7.6 g/cm3 target where geometry, SMC grade, and compaction route allow | Density affects permeability, loss behavior, mechanical strength, and the repeatability of thin tooth or sector features. |
| Insulation and bonding readiness | Resin insulation coating, optional Hi-pot scope, adhesive or curing boundary, and winding-clearance review | A magnetic core still has to survive winding, assembly, thermal exposure, and supplier-quality release. |
| Dimensional control | Drawing-dependent precision machining and inspection | Small axial air gaps make flatness, parallelism, and segment position critical to torque and noise. |
| Loss validation | Frequency and flux-density dependent test plan | Core loss must be evaluated under the customer operating point, not only by catalog material data. |
The focus is the magnetic core or stator component. We support manufacturable SMC core parts that motor OEMs can integrate with their windings, magnets, rotors, housings, and drives.
We can review one-piece circular cores, sector or fan-shaped segments, segmented stator concepts, individual teeth, and optimized 3D tooth or yoke features when the buyer provides CAD and operating requirements.
No. They are RFQ planning ranges. Final manufacturability depends on CAD geometry, SMC grade, compaction direction, demolding, density target, tooling route, and validation method.
Yes, resin insulation coating before winding can be scoped when the coating area, thickness expectation, slot clearance, Hi-pot need, and acceptance method are defined in the project review.
It can be reviewed as a project-specific scope. The RFQ should separate pressed core supply, machining, coating, adhesive bonding, curing, carrier integration, and packaging so engineering and purchasing compare the same boundary.
Yes. Early CAD is useful for DFM and magnetic-part feasibility before the customer commits to compaction tooling.
Inquiry Email
Attach STEP/DXF/PDF plus frequency, flux density, sample quantity, annual forecast, and destination.
