16:17 27-01-2026

VariTwist project reduces hairpin stator production costs for electric motors

The Production Engineering of E-Mobility Components (PEM) department at RWTH Aachen University has completed the variTwist research project, which aimed to reduce the production costs of electric motors. This project was carried out in collaboration with Röscher GmbH and supported by the German Federal Ministry for Economic Affairs and Energy.

As part of the project, a new process station was developed for twisting copper flat conductors in so-called Hairpin stators. This step is considered one of the most expensive in electric motor production. According to PEM, traditional equipment for this operation costs between 100,000 and 200,000 euros, while the new technology can perform the process with tooling costs of less than 1,000 euros.

This development is particularly important for prototypes and small-scale production, where high tooling costs limit flexibility and speed in introducing new solutions. The new system also shortens delivery times and simplifies adaptation to different design variants.

Hairpin technology is widely used in modern electric drives due to growing demand for electric vehicles. PEM notes that the variTwist solution could increase the accessibility of electric drives and accelerate the development of the segment, including city electric cars, by reducing production costs.