Laser-cut laminations: from prototype to electric motor

The acceleration toward electric mobility and the growing demand for energy efficiency in industrial settings have, in recent years, generated an unprecedented need for new designs and prototype solutions for laminated stacks and stator/rotor laminations. This trend has compelled electric motor manufacturers to develop prototypes and small batches in increasingly shorter timeframes, while maintaining high quality standards. In this context, the need arises for specialized technology partners capable of bridging the gap between design and series production through advanced laser technologies and high-level expertise. Furthermore, the shift from a linear to a circular economy has increased demand for the repair and revamping of electric motors manufactured in the 1950s and 1960s, creating a niche market that requires equally specialized technical skills and highly flexible manufacturing capabilities.

As a business unit of Carbonveneta, the Vicenza-based Nestech operates within this market segment, offering advanced laser-based technological solutions for the production of laminated stacks and electric motor components.

Low-power cutting technologies for high-precision results

Founded in 2017 and already boasting a noteworthy portfolio of international clients, Nestech has focused from the outset on laser systems specifically engineered for the precision processing of thin-gauge materials. This strategic choice differentiates the company from competitors using standard sheet metal processing equipment.

«Our laser cutting machines – declares co-owner and Sales Manager Roberto Movio – are not generic sheet metal systems, but were expressly designed to process ultra-thin thicknesses».

The company’s evolution has followed a steady, incremental growth path. After an initial phase in which laminations were sourced from external partners, Nestech installed its first custom laser system at the Valdastico (VI) production site in 2019. This was followed by a second system in 2021 and a third scheduled for installation in October 2025, further boosting production capacity. Each machine is specifically optimized for electromechanical applications, featuring a working area of up to 1,500 x 3,000 mm, a swappable worktable to reduce downtime, 2 kW of power, and a beam diameter of 50 microns.

«The choice of low power – emphasizes Movio – was made to ensure minimal thermal impact, both on the metal and on the coating. This configuration allows us to work with absolute precision and quality on thicknesses ranging from 0.1 to 3 mm, creating very narrow bridges relative to thickness without compromising material integrity. Thanks to over 30 years of experience in the electric motor industry, we understand very well the limits and potential of laser cutting compared to punching. Our machines are specifically designed to minimize distortion and achieve performance comparable to a final product».

Beyond stacking and bonding

In addition to cutting technologies, Nestech’s technological portfolio covers the full production chain of electromechanical components, including finishing and assembly. One of the company’s key differentiators lies in its stacking process. Laminations are assembled using custom-designed equipment developed by the technical department with 3D software and built specifically for each project, ensuring the highest quality of the final product. Pressing is performed using tie rods and springs or hydraulic presses, depending on the size and volume requirements. Nestech handles a wide dimensional range—from very small components to large, complex assemblies. Final assembly relies mainly on Backlack bonding technology (used in 80% of production), which involves heat-activated, pre-insulated epoxy resin.

«Compared to welding – explains Movio – bonding ensures greater compactness and significantly reduces the risk of short circuits».

For specific applications requiring alternative joining methods, the company is equipped for TIG and MIG welding of stator or rotor stacks, as well as for brazing aluminum or copper bars along with the corresponding rotor stack end caps. High-precision machining operations, such as turning on assembled stator and rotor stacks, ensure tight tolerances, with lathes capable of handling diameters up to 2,000 mm.

Integrated solutions for stators and rotors

Nestech’s offering is further enriched by winding services and integrated rotor-stator solutions.

«Currently – clarifies Movio – we do not manufacture complete stators in-house, but we work closely with a specialized partner. Upon request, we can also supply stators complete with windings, resin encapsulation, or potting. This marks an evolutionary step in our stator-related offering».

Regarding rotor stacks, Nestech provides permanent magnet assembly up to shaft integration. Through its business unit dedicated to the production and processing of carbon fiber profiles, the company also offers rotors with external magnets wrapped in carbon fiber.

«In the case of rotors with external magnets – explains Movio – the small visible tabs serve to position the magnets. These are then held in place with a carbon fiber wrapping. The filament is applied under controlled tension and then turned to ensure concentricity and dimensional tolerances».

All process technologies are fully integrated within an Industry 4.0 environment, featuring a centralized management system, machine-mounted terminals, and barcode traceability to guarantee complete control over the production process.

Market strategy and product diversification

Nestech’s commercial strategy is structured around three main pillars, aligned with the diverse needs of its market. The first focus remains traditional prototyping, with deliveries ranging from one to a few units for clients seeking to validate their designs prior to investing in tooling. The second area involves small production batches for clients whose volumes do not justify dedicated punching investments.

«The third area – continues Movio – involves segments related to service and repairs, where time is a critical factor, taking precedence over purely economic considerations».

This strategic diversification has enabled Nestech to develop a broad and balanced customer portfolio, now comprising over 300 active clients—30% in Italy and 70% abroad—across markets such as the Middle East, Canada, the United States, and the Far East. The application sectors are equally varied, ranging from traditional industries (woodworking machines, packaging, positioning systems) to robotics. Other fields include renewable energy (hydroelectric and wind generators), oil & gas (new-generation machines), and aerospace. Notably, despite not holding formal aerospace certifications, Nestech has been qualified by two international aerospace groups through comprehensive audits covering its entire production chain.

«More generally – states Movio – we are able to serve any application that requires electric motors or generators with non-standard geometries, or where high flexibility and fast turnaround are essential».

Quality control and certification for advanced markets

Nestech’s competitiveness in both national and international markets is built on high quality standards, supported by significant investments in quality control systems and certification. ISO 9001 certified, the company has invested in advanced quality inspection equipment, including 2D scanning CMMs for individual laminations and 3D contact CMMs for assembled stacks.

«This allows us – notes Movio – to certify every component, ensuring traceability, compliance, and repeatability of results, with prototypes that are as close as possible to the final product. Our mission is to provide high-quality, value-added solutions, so that the prototype closely matches what the final product will be».

This philosophy is key to ensuring that laboratory tests on prototypes yield performance data consistent with those of the final product, thereby avoiding discrepancies that could derail the entire development process. Quality also extends to logistics and shipping, with each component packaged in custom-made wooden crates equipped with protective materials and anti-corrosion paper to safeguard integrity during transport.
«Each shipment – underlines Movio – is designed ad hoc depending on the material type and destination».

Strategic vision and future developments

With annual revenues exceeding €2 million, Nestech is planning to expand its production facilities beyond the current 2,000+ sqm covered area (where about 15 employees operate) and to install a photovoltaic system as part of an ESG strategy culminating in the release of its first sustainability report by year-end. In line with ongoing investments, Nestech’s growth strategy focuses on expanding its service offerings while maintaining its emphasis on high-tech products. The company is currently developing its capacity to deliver stators with integrated windings, resin encapsulation, and potting, as well as rotor assemblies with bonded permanent magnets and carbon fiber wrapping—leveraging the expertise of Carbonveneta’s composites division.

«Our goal for the coming years – concludes Movio – is to further expand the technical office to meet the growing demand for complete electric motor development».

This ambitious vision positions Nestech as a strategic partner capable of supporting customers throughout the entire electric motor development cycle—from design to prototype and small batch manufacturing, including housings, bearings, windings, and testing.

(by Gianandrea Mazzola)