Tech Torqs #4: What is FiberPrinting™?

Inspired by traditional textile looms, FiberPrinting™ brings a revolutionary approach to stator winding. Rather than hand-wrapping or automated slot winding, this technique “weaves” copper conductors into a mat with unprecedented density and repeatability.

How FiberPrinting™ Works

1. Warp & Weft Setup
   • Warps: Three fixed copper yarns correspond to each motor phase.
   • Wefts: A fourth copper thread is interlaced crosswise, creating a robust stator mat.
2. Precision Weaving Patterns
   • Specially developed algorithms control tension and path, ensuring each layer aligns perfectly.
   • Resulting mats exceed traditional fill factors, packing more copper into the same slot area.

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Key Benefits

• Ultra-High Copper Density
  Achieve up to 60% fill—far beyond conventional methods—for higher torque and efficiency.
• Repeatability & Quality
  Automated weaving guarantees identical stator mats batch after batch, reducing scrap and rework.
• Rapid Design Flexibility
  Switching between winding patterns or motor sizes takes minutes, not days—ideal for prototyping or low-volume runs.

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Why It Matters

FiberPrinting™ fuses the artistry of weaving with the precision of modern automation. By treating copper wires like yarns, motor designers unlock new SWaP-optimized performance, smoother torque output, and accelerated time-to-market.