Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM
Precision laser cutting and lamination stack production for electric drives
The core of an electric drive plays a decisive role in determining efficiency, power density, and overall performance. Precisely cut stator and rotor sheets reduce eddy current losses, enhance magnetic properties, and allow higher rotational speeds. Through high‑precision laser cutting of electrical steel and production‑oriented lamination stack design, we support both research and development projects as well as industrial applications.
What are the benefits of laser cutting electrical steel for research and industry?
Tool‑free laser cutting of electrical steel offers maximum design flexibility with minimal lead times. New topologies, variant comparisons, or complex geometries can be implemented quickly – ideal for prototypes, small motor models, transformers, or small‑batch production. CAD‑based designs can be directly transformed into precise stator and rotor laminations.
What services does lamination stack production at Fraunhofer IFAM include?
We offer the complete range of manufacturing and development services — from individual laminations to fully assembled stacks:
- Precision laser cutting of electrical sheets
- Production of stator, rotor, and transformer stacks
- Manufacturing of segmented lamination stacks
- Stacking by bonding/baking or welding
- Production of single parts and small batches
- Use of state‑of‑the‑art 2D / 3D metrology for precise geometric evaluation
- Application of 2D / 3D simulation models for electromagnetic assessment and mechanical stress analysis
- Feasibility studies for new lamination geometries
- Variant studies and prototype production
The advantages of combining development and manufacturing
The close integration of manufacturing technology, applied materials research, and electric machine design unites electrical engineering expertise with production know‑how — enabling comprehensive evaluation of results. Customers benefit from well‑founded decision‑making tools, digital models, and targeted consulting, aimed at reducing development risks and cutting costs in serial production projects.
Which materials can be laser‑cut?
Depending on the application, we process a wide range of materials and thicknesses:
- Electrical steel up to 1 mm
- Copper up to 2 mm
- Aluminum up to 2 mm
- Brass up to 3 mm
- Mild steel and stainless steel up to 3 mm
- Titanium up to 2 mm
Additional materials and thicknesses are available on request. Material can be provided by the customer.
What technical capabilities are available?
Modern fiber laser technology enables highly precise cutting with minimal heat‑affected zones. The process is complemented by comprehensive 2D and 3D measurement systems for quality assurance. This ensures accurate geometry, clean edge quality, and reliable evaluation of magnetically relevant properties.
Who benefits most from our services?
Our offer is aimed at electric machine manufacturers, suppliers, OEMs, and research institutions that require lamination stacks for electric drives — particularly when high flexibility, short production times, and scientific support are essential.
How do customers benefit in practice?
- High flexibility in geometry and quantity
- Rapid response to manufacturing requests
- Tool‑free production of prototypes and small series
- Combination of development expertise and validated manufacturing services
- Holistic evaluation of performance and manufacturing quality
The result: Precise electrical steel stacks ready for testing or direct integration into drive systems – providing a reliable foundation for the efficient electric drives of tomorrow.