A hairpin stator uses pre-formed rectangular copper conductors (hairpin-shaped) inserted into stator slots and welded at the ends, replacing traditional round-wire windings. This design achieves higher copper fill factor (≥92%), better thermal dissipation, and significantly improved power density — making it the preferred choice for UAV propulsion and EV traction motors.

Reenives manufactures precision hairpin stators with 0.20mm silicon steel laminations and C5 epoxy coating — achieving stacking factor ≥98.2% and supporting high-frequency PWM operation up to 80kHz.

Reenives offers hairpin stators in multiple configurations to meet diverse application requirements:

• By Winding Type: Concentrated hairpin winding (high torque density), distributed hairpin winding (smooth operation), and continuous hairpin (no welding joints).
• By Slot/Pole Config: 12N10P, 12N14P (UAV), 24N20P, 48N40P (EV traction).
• By Conductor Layer Count: 2-layer, 4-layer, 6-layer, 8-layer, up to 16-layer for extreme power density.
• By Insulation System: C3 (standard), C5 epoxy coating (Class H, 200°C), and oil-cooled compatible variants.

💡 Reenives specialty: private mould development for custom hairpin stator geometries — including Halbach array configurations for UAV applications achieving 25 Nm/kg torque density.

All parameters validated by Reenives R&D center and third-party testing per IEC 60404-2. Hairpin stator data from TECO T Power Air UAV system and IEEE validation studies.

📐 Data source: Reenives quality assurance lab, TECO UAV powertrain test reports. Full batch traceability and test certificates available.

Reenives hairpin stators power critical applications across multiple sectors:

• Commercial UAVs & eVTOL: Hairpin stators achieve +20% flight time over conventional BLDC motors — 76.5kg thrust per shaft for 10-100kg payload drones.
• Electric Vehicle Traction Motors: 48V–800V hairpin stators for e-bikes, e-scooters, passenger EVs, and next-generation 16-layer winding designs.
• Agricultural Spraying Drones: Dust/water-resistant C5 epoxy coating with 500h salt spray resistance.
• Electric Aircraft Propulsion: High-power-density hairpin windings for aviation propulsion systems under high-frequency PWM drive conditions.
• Industrial BLDC Actuators: Robotic arms, servo drives, and medical equipment.

1. Define power and voltage targets: Determine peak power (e.g., 12.5kW UAV motor), voltage (48V–800V), and base speed.
2. Choose lamination material thickness: 0.20mm for high-frequency operation (40-80kHz PWM) to minimize core loss.
3. Select slot/pole and layer count: 12N14P for UAV/eVTOL; 24N20P+ for EV traction. Higher layer count (8-16 layers) reduces AC losses but increases manufacturing complexity.
4. Specify insulation and cooling: C5 epoxy coating for outdoor UAVs; oil-compatible insulation for EV applications.
5. Request samples and validation: Reenives delivers hairpin stator samples with FAI reports and insulation test certifications. Prototype samples ready in 7-10 days.

💡 Engineering support: Free DFM within 48h — send your motor spec or drawing to linda_reenives@163.com.