Custom Axial Flux Micro Motor Stator Core Laser Cut Wound Core for Precision BLDC & Robotic Actuators

Engineering Overview: Precision Axial Flux Micro Motor Stator Cores

Shunge Steel manufactures custom, high-precision axial flux micro motor stator cores in Foshan, Guangdong, China. Engineered specifically for miniature high-torque and ultra-compact motion systems, our wound axial flux cores deliver exceptional power density in constrained axial spaces where conventional cylindrical (radial flux) micro motors cannot fit.

Unlike traditional radial micro motor stators that rely on complex stamped lamination tooling, our axial flux micro stator cores are produced through precision tape winding of ultra-thin electrical steel strips (0.10 mm to 0.35 mm), followed by high-accuracy CNC laser cutting to form custom tooth and slot profiles (such as 6-slot, 8-slot, 12-slot, or custom skewed geometries). This process eliminates expensive stamping die investments, enabling rapid prototyping, flexible design iterations, and highly cost-effective batch manufacturing for medical tools, robotics, optical devices, and aerospace micro-actuators.

Key Technical Advantages of Shunge Micro Motor Cores

• Ultra-Compact Micro Envelope & High Torque Density: The flat disc topology allows magnetic flux to interact over a large active surface area parallel to the shaft, generating up to 2x higher torque density per unit volume compared to conventional cylindrical micro motors.
• Zero Tooling Cost via CNC Laser Slotting: Slot profiles, tooth count, slot width, and central mounting apertures are generated entirely via programmable laser cutting. Engineering changes and prototype iterations require no stamping dies.
• Ultra-Thin Steel Strip & Reduced High-Frequency Losses: Available in ultra-thin electrical steel grades (0.10 mm, 0.15 mm, 0.20 mm, and 0.35 mm), significantly suppressing eddy current losses during ultra-high-speed or high-frequency micro motor operation.
• Seamless Continuous Tape-Wound Back-Iron: Formed from continuous coiled electrical steel strip, eliminating inter-segment air gaps, stabilizing the magnetic circuit, and minimizing cogging torque and acoustic vibration in precision instruments.
• Sub-Millimeter Dimensional Accuracy: Precision laser control keeps slot positional tolerances within ±0.03 mm and burr heights below 0.015 mm, protecting delicate micro-winding insulation.

Technical Specifications & Parameter Matrix

High-Precision Micro Motor Application Scenarios

Our custom axial flux micro motor stator cores provide the ideal magnetic core foundation for high-end micro-motion applications:

• Medical Devices & Surgical Power Tools: Ultra-quiet, low-vibration micro BLDC stators for surgical bone drills, dental handpieces, precision infusion pumps, and laboratory centrifuges.
• Humanoid Robotics & Bionic Micro-Joints: Pancake form factor fits snugly inside miniature robotic fingers, wrist rotators, and exoskeleton joint actuators where high peak torque is required in limited axial depth.
• Precision Optical Gimbals & Laser Scanners: Low cogging torque and high angular resolution for multi-axis UAV camera gimbals, LiDAR scanning mirrors, and optical tracking platforms.
• Miniature Industrial Pumps & Semiconductor Handling: High-efficiency continuous operation for chemical micro-metering pumps, vacuum wafer positioning robots, and aerospace micro-valves.

End-to-End Prototyping & Customization Workflow

1. Drawing & Spec Review: Send your 2D/3D CAD drawings (DXF, DWG, STEP) or dimension parameters (OD, ID, Height, Slot Count). Our engineering team reviews magnetic feasibility and tolerance alignment.
2. Precision Strip Winding: Coiled electrical steel strip is wound under closed-loop tension control to achieve the exact target disc dimensions and high stacking density.
3. CNC Laser Slotting: Programmable multi-axis laser cut lines form slot openings, mounting holes, and tooth profiles with ultra-sharp precision and clean edges.
4. Deburring & Surface Treatment: Precision deburring eliminates microscopic edge burrs; cores can undergo stress-relief annealing or varnish impregnation as required.
5. Quality Verification & Fast Dispatch: Finished cores undergo full dimensional and roundness checks on testing jigs before secure export packaging.

Rigorous Quality Assurance Standards

• Raw Coil Verification: Raw electrical steel coils are tested for magnetic permeability and specific core loss (W/kg) via Epstein frame testers prior to slitting.
• Winding Density & Layer Alignment: Strict monitoring of winding tension ensures stacking factor ≥96.5% with uniform radial wall thickness.
• Laser Cut Slot Dimensional Inspection: High-magnification optical profile projectors ensure tooth width, slot opening, and radial depth stay strictly within ±0.03 mm.
• Roundness & Flatness Verification: Precision CMM and dial indicators verify outer diameter roundness and axial face flatness (≤0.08 mm).

Export Packaging & Logistics Protection

• Moisture-Proof VCI Barrier Sealing: Individual vapor corrosion inhibitor wrapping protects finely ground electrical steel surfaces against marine humidity and oxidation.
• Custom Molded Foam Trays: Shock-absorbing CNC cut foam trays prevent slot tooth distortion and edge contact during transit.
• Reinforced Export Packaging: Packed in heavy-duty corrugated cartons or fumigation-free plywood crates for worldwide air and ocean freight.

Frequently Asked Questions (FAQ)

Q1: What is the main advantage of an axial flux micro motor core compared to a radial flux micro motor?
A: An axial flux micro motor core utilizes an axial magnetic field crossing the air gap parallel to the rotor shaft. This disc-shaped geometry maximizes the active torque-generating surface area within a remarkably short axial length, delivering up to double the torque density of cylindrical radial motors while significantly reducing overall drive weight.

Q2: Do we need to pay for tooling or stamping dies to make a custom 6-slot or 12-slot micro core?
A: No. Because our slot features and tooth shapes are formed via high-precision CNC laser cutting on wound cores, there is zero stamping die tooling cost. You can modify slot geometries or test prototype tooth counts without paying for new dies.

Q3: What electrical steel thickness options do you offer for high-speed micro motors?
A: We routinely process ultra-thin electrical steel strips ranging from 0.10 mm, 0.15 mm, and 0.20 mm up to 0.35 mm. For high-speed micro motors operating at high electrical frequencies, thinner material dramatically reduces eddy current core losses and thermal rise.

Q4: Can Shunge Steel manufacture miniature stators with hollow central bores?
A: Yes. Inner diameters can be customized down to Ø 8 mm or enlarged to accommodate hollow-shaft designs, optical beam paths, slip rings, or internal cable routing for robotic joints.

Q5: What is the turnaround time for micro motor core prototypes?
A: With our no-die laser manufacturing process, engineering prototypes are typically produced, inspected, and dispatched within 7 to 15 business days following CAD drawing sign-off.