Custom SMC stator segments and tooth modules for axial flux motors with modular tooling, winding access, pitch control, retention, and validation records.
Use this segment datasheet as an RFQ planning map. A single SMC segment has to be reviewed against the full stator assembly, winding process, retention method, pitch fixture, and validation package before tooling release.
| Parameter | RFQ Planning Range | Engineering Note |
|---|---|---|
| Parent stator envelope | OD 30-800 mm; ID 25 mm min.; axial height 5-110 mm | The segment is reviewed against the assembled stator envelope, not only as an isolated tooth. |
| Segment / tooth position count | 3-112 positions around the stator | Repeatability, cumulative pitch error, and fixture access become more important at high count. |
| Segment shape families | Circular arc segment, sector/fan segment, individual tooth module, grouped tooth module, or YASA-style tooth module when buyer topology and IP boundary allow | Shape selection should be tied to compaction direction, demolding, winding access, magnetic path, retention, and inspection datum access. |
| Tooth and segment CTQs | Tooth height, tooth-head width, tooth-root radius, side-wall angle, slot opening, sector angle, draft, chamfer, datum face, and edge condition | Fragile corners and narrow tooth roots should be screened for green strength, ejection, chipping, density variation, and inspection access. |
| Pitch and air-gap control | Segment pitch, cumulative pitch error, fixture datum, assembled circularity, flatness, parallelism, and stator-to-rotor air-gap stack-up | A stable assembly fixture and inspection method should be planned before pilot sampling because small segment errors accumulate. |
| Retention / holder interface | Nonmagnetic holder, carrier, adhesive, clamp ring, overmold, potting, encapsulation, or housing feature | Mechanical retention affects datum surfaces, magnetic gap, winding sequence, thermal path, and supplier responsibility. |
| Winding access and insulation | Individual tooth winding, grouped module, bobbin, concentrated winding, flat-wire feasibility, resin coating, masking, Hi-pot, impregnation, and potting clearance | Segment shape should leave practical clearance for copper, insulation, coating thickness, thermal path, and assembly tooling. |
| Encapsulation / potting / bonding boundary | Loose segment, coated segment, carrier-ready tooth, bonded module, potted module, or buyer-assembled stator scope | Quote pressed segments, coating, bonding, potting, holder integration, and assembled-stator evidence as separate scope items. |
| Material and density planning route | Buyer-nominated or performance-selected SMC route; 7.4-7.6 g/cm3 target where geometry and compaction route allow | Density targets should be confirmed on the actual segment geometry, not copied from a public material benchmark. |
| Inspection and release package | FAI, CMM or 3D scan, CTQ table, density or weight record, crack/chip visual check, pitch fixture note, coating or Hi-pot note, and packing record | Engineering, sourcing, and SQE should agree which records are required 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
Segment CAD, full stator assembly, drawing revision, parent OD/ID/height, segment count, slot/pole count, air-gap datum, and CTQ list.
Acceptance Focus
Prevents a good-looking segment from failing after circular pitch, rotor clearance, or assembly stack-up is reviewed.
Evidence to Prepare
Holder or carrier model, adhesive or clamp plan, potting or encapsulation boundary, housing interface, axial pull or vibration assumptions, and assembly sequence.
Acceptance Focus
Reduces late supplier disputes where the pressed part is acceptable but the assembled stator cannot be retained or validated.
Evidence to Prepare
Winding route, bobbin or coil model, coating area map, coating thickness expectation, masking boundary, Hi-pot need, impregnation or potting clearance, and visual criteria.
Acceptance Focus
Protects copper fill, slot clearance, insulation reliability, and thermal path before the buyer commits to the segment geometry.
Evidence to Prepare
FAI, CMM or 3D scan, density or weight record, visual crack/chip notes, pitch fixture record, assembled gap record, coating or Hi-pot note, traceability, and packing record.
Acceptance Focus
Turns early segment samples into auditable evidence for design review, supplier approval, pilot sourcing, and repeat-order control.
| Buyer Checkpoint | Evidence to Prepare | Acceptance Focus |
|---|---|---|
| Can the segment drawing be connected to the full stator assembly before quotation? | Segment CAD, full stator assembly, drawing revision, parent OD/ID/height, segment count, slot/pole count, air-gap datum, and CTQ list. | Prevents a good-looking segment from failing after circular pitch, rotor clearance, or assembly stack-up is reviewed. |
| Can retention, holder, potting, and housing responsibility be audited before tool release? | Holder or carrier model, adhesive or clamp plan, potting or encapsulation boundary, housing interface, axial pull or vibration assumptions, and assembly sequence. | Reduces late supplier disputes where the pressed part is acceptable but the assembled stator cannot be retained or validated. |
| Can winding, insulation, coating, and Hi-pot scope be checked before samples ship? | Winding route, bobbin or coil model, coating area map, coating thickness expectation, masking boundary, Hi-pot need, impregnation or potting clearance, and visual criteria. | Protects copper fill, slot clearance, insulation reliability, and thermal path before the buyer commits to the segment geometry. |
| Can engineering, sourcing, and SQE receive one segment-to-assembly release package? | FAI, CMM or 3D scan, density or weight record, visual crack/chip notes, pitch fixture record, assembled gap record, coating or Hi-pot note, traceability, and packing record. | Turns early segment samples into auditable evidence for design review, supplier 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 |
|---|---|---|
| Segment repeatability | Tooth height, datum faces, pitch feature, slot opening, and fixture-controlled circular position | A small error per segment can create large circular pitch and air-gap variation in the final stator. |
| Tooling flexibility | Modular compaction tooling for individual segments, grouped teeth, or sector modules before full-ring commitment | Segmented concepts can shorten early validation cycles and reduce full-ring tooling exposure. |
| Winding accessibility | Individual tooth winding, bobbin, concentrated winding, flat-wire feasibility, coating, impregnation, and potting clearance | The business case for segmented stators often depends on simpler winding access and higher copper-fill feasibility. |
| Retention readiness | Holder, carrier, adhesive, clamp ring, potting, encapsulation, housing feature, or buyer-defined assembly fixture | Independent segments need a clear mechanical load path before pilot sourcing or customer validation. |
| Evidence package | FAI, CMM or 3D scan, density or weight record, pitch fixture note, gap record, coating or Hi-pot note, and magnetic report when scoped | Segment samples are useful only when the buyer can trace them to the assembly condition being approved. |
No. Segments can be used for prototypes or production when they improve winding access, repairability, tooling economics, or packaging.
Segments can be better when the program needs lower early tooling exposure, easier winding, serviceable modules, smaller press-tool risk, or staged validation. A one-piece stator may still be better when pitch, retention, and assembly cost dominate.
Yes, when the buyer provides the controlled topology, tooth drawing, full assembly envelope, retention concept, and IP boundary. For highly YASA-specific tooth modules, review the YASA Segmented Stator Teeth page as the deeper RFQ path.
The RFQ can review nonmagnetic holders, carriers, clamp rings, adhesive bonding, potting, encapsulation, housing features, and buyer-defined fixtures. Final validation should state the load, thermal, vibration, and acceptance boundary.
Pitch risk is managed by defining datum faces, tooth or segment CTQs, fixture method, cumulative pitch tolerance, assembled gap inspection, and release records before pilot sampling.
They can be scoped when the buyer provides coil or bobbin information, coating area, thickness expectation, voltage or Hi-pot need, masking boundary, impregnation or potting plan, and visual criteria.
A practical sample package can include FAI, CMM or 3D scan, CTQ table, density or weight record, visual crack/chip notes, pitch fixture result, assembly gap note, coating or Hi-pot record, magnetic data when scoped, traceability, and packing record.
Inquiry Email
Attach STEP/DXF/PDF plus frequency, flux density, sample quantity, annual forecast, and destination.
