NESTECH supports engineers and producers in the manufacturing of single laminations, complete custom laminated stator and rotor cores, ready for physical testing and validation in short timeframes. Thanks to its rapid prototyping service, customers can quickly obtain design feedback and accelerate the product iteration and optimization process before proceeding with serial production.
NESTECH guarantees:
- Short lead times
- High precision, even with complex geometries and special materials
- Flexible production, from single pieces to small batches
- High value engineering support: from CAD file to real prototype
This service is intended for:
- R&D Departments to test new geometries, materials and solutions before serial production;
- Engineering Departments to validate design changes or optimize the performance of magnetic components;
- Research Centers and Universities that require physical prototypes for experiments, materials testing, and the study of new geometries.
What NESTECH does
- Rapid production of laminations based on CAD drawings
- Manufacturing of complete laminated cores (rotors and stators), even in small quantities
- Prototypes ready for testing, even on complex geometries
- Engineering and manufacturing of dedicated tools for stacking and pressing
- Management of innovative materials: thin magnetic steels (e.g., NO10, NO20, NO27).
Technical know-how to support innovation
NESTECH is at the forefront of prototype manufacturing for:
- Reluctance motors
- Permanent magnet (PM) motors
- Hybrid PM + reluctance solutions
Every day NESTECH supports engineers and R&D centers in the conception of evolving geometries, with different quantities and positions of magnets, variable slots and complex shapes.
Advanced technologies and materials
To ensure high performance and reliability in stator and rotor prototypes, NESTECH use cutting-edge technologies and selected materials that meet the most advanced requirements in terms of magnetic efficiency, precision and insulation values.
The company is able to cut low gauge laminations (N010, N020, N027) to reduce losses and eddy currents
NESTECH uses backlack coated electrical steel for high magnetic efficiency and insulation without metal-to-metal contact
Extremely controlled, low-power fiber laser cutting machines are used, to preserve the steel structure and edge insulation.
Backlack technology
NESTECH uses BACKLACK technology for cores manufacturing. The single laminations are cut from electrical steel pre-insulated with epoxy resin. When heated to approximately 200°C, the resin cures, allowing the laminations to bond together.
The advantages of this technology are:
- Minimized deformation of the stacks
- Improved rigidity and stability of the stacks
- No vibrations
- Improved precision in lamination alignment
- Improved perpendicularity and flatness of the stacks
- No disturbances in the magnetic field due to welding.
Benefits of prototyping service
- Quick manufacturing times: prototypes can be produced in short time frames, accelerating the development process.;
- High precision: our fiber Laser machines guarantees tight tolerances, ensuring components fully compliant to drawings;
- Initial cost savings: no need of stamping tools, therefore our solution is ideal for initial development and small series, optimizing costs right from the start.;
- Design flexibility: we quickly adapt cutting and stacking parameters to any design variant, simplifying changes between different issues of drawings and prototypes;
- Continuous technical support: we offer assistance throughout the entire process, from design to delivery, with expert and qualified personnel.
Two examples of tailor-made solutions
1. Laminated rotor core for permanent magnet synchronous motors with radial magnets, complex geometry, produced for a research and development application.
2. Laminated core for an electric machine required for a research and development project, pressing plates, bonded laminations. Complete core CNC reworking after stacking and assembly.
