Electric motor hairpin processing

Electric motor copper hairpins with enamel removed by a CO2 laser
Electric motor copper hairpins with enamel removed by a CO2 laser

Electric vehicle motors use copper “hairpins”, rectangular copper wires up to 6mm wide coated with a dielectric enamel (PEEK, PFA-PI, PA), to provide electrical isolation; this enamel must be partially removed so that the hairpins can be welded for electrical contacting.

Unlike mechanical methods, laser processing is contactless, without ablation or loss of copper, and with very little downtime or tooling needed for any changes. A galvanometer scanner passes the laser beam rapidly over the required area, with the hairpin positioned at an angle; in this way, two lasers can be used to process all sides simultaneously.

A CO2 laser source ablates the enamel coating from an electric motor hairpin
A CO2 laser source ablates the enamel coating from an electric motor hairpin

Enamel ablation using our CO2 lasers is a very fast process. Removal rates depend on the type and thickness of coating, as well as the coating method (cross layer), but there is no material loss (cost of copper) when a CO2 laser is used.

SR series

Watertight laser technology

MULTISCAN VS

MULTISCAN® VS

125W sealed CO2 laser marking system

MULTISCAN HE
MULTISCAN HE

MULTISCAN® HE

125W sealed CO2 laser marking system

Applications laboratories

Could a laser be used to improve your manufacturing process? We can help you to find out by testing samples of your material or product in one of our applications labs. Our applications lab facilities are open to both new and existing customers and OEMs. Our laboratories are well equipped to carry out a range of processes including cutting, marking, engraving, drilling, scribing, ablation and more. We offer rapid sample turnaround times, detailed application reports, and complimentary advice from our experienced applications engineers. Whatever your process, we can help you to determine the best laser for your application.