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Cast coil Technology
Next Generation E‑Drives!

Cast Coil Icon Patent
up to 0 % fill factor
Cast Coil Icon Temperature
lower temperature better heat dissipation
castcoil Icon Sizing flexibility

flexible in quantity size geometry material

Cast Coil Icon Sustainabilty
0 % lower emissions

CAST COILS – NEXT GENERATION E‑DRIVES!

A wide range of requirements are placed on the windings of electrical machines. On the one hand, the maximum performance of the electrical machine should be achieved by a high slot fill factor and thus the best possible utilization of the available installation space. On the other hand, the best possible cooling of the conductors must be ensured and the occurrence of additional losses due to current displacement must be avoided. There is an overarching desire for cost-effective and automatable production and assembly of the coils.

We developed a process which allows coils for electrical machines to be manufactured by casting. The coil geometries with flat conductor arrangement which can be manufactured using this process offer decisive advantages over conventionally manufactured windings. The casting production can be carried out either by die casting, low-pressure casting or investment casting and the coils can be cast from copper as well as aluminum.

Aluminum Cast Coils

Energy Efficient | Economic | Sustainable

Aluminum Cast Coils Energy Efficient | Economic | Sustainable
Cast Coil GmbH Line
Cast Coil GmbH
Copper Cast Coils
Cast Coil GmbH Line
Cast Coil GmbH

Copper Cast Coils

High performance | Economic | Sustainable

Goodbye old-fashioned windings – Welcome Cast coils

E-Drives inspire rail transport
Electric trains are already state of the art in railway transport. Next, CastCoils will revolutionize energy efficiency and performance of electric drives for trains.
E-Drives inspire urban traffic
E-drives create new solutions in growing urban areas. With our new technology, size and weight are significantly reduced.
E-drives inspire the automotive industry
The future of e‑mobility! E‑mobility is conquering the automotive market. CastCoils ensure an extended range and higher energy efficiency.
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The benefits of cast coils

Conventional Copper coils

Conventional Copper coils

Copper castcoils

Copper castcoils

Aluminum castcoils

Aluminum castcoils

CO2 reduction

Aluminum enables lower energy consumption in production and recycling, 30% lower CO2 emissions and the use of CFC-free refrigerants in refrigeration and air conditioning technology.

CONVENTIONAL COPPER COILS

Conventional Copper coils

COPPER CASTCOILS

Copper castcoils

ALUMINUM CASTCOILS

Aluminum castcoils
Performance

Tested electric drives for e-bikes achieved, compared to drives with traditional wound copper coils, up to 50% higher continuous torque with aluminum CastCoils and 100% higher continuous torque with copper CastCoils.

CONVENTIONAL COPPER COILS

Conventional Copper coils

COPPER CASTCOILS

Copper castcoils

ALUMINUM CASTCOILS

Aluminum castcoils
Weight reduction

A cast aluminum winding is 40% lighter than a conventional copper winding.

CONVENTIONAL COPPER COILS

Conventional Copper coils

COPPER CASTCOILS

Copper castcoils

ALUMINUM CASTCOILS

Aluminum castcoils
Space utilization

Slot fill factor of up to 90% compared to current maximum of 55%.

CONVENTIONAL COPPER COILS

Conventional Copper coils

COPPER CASTCOILS

Copper castcoils

ALUMINUM CASTCOILS

Aluminum castcoils
Heat dissipation

Combination of high slot filling factor and excellent thermal behaviour allows to double the current density per slot area.

CONVENTIONAL COPPER COILS

Conventional Copper coils

COPPER CASTCOILS

Copper castcoils

ALUMINUM CASTCOILS

Aluminum castcoils
Wind power
Wind energy is a booming market. Large offshore areas require many thousands of e-drives. Low weight and maximum energy efficiency are the winners.
Power generation
Energy generation transforms natural energy into valuable electricity. This requires power generators of the highest energy efficiency.
Shipping
The ship market is changing. Climate change requires electric drives. CastCoils enable energy efficiency, better performance and increased range.
Aviation
E-drives with high performance and lowest possible weight are demanded for the expanding market of electric aviation. CastCoils make this possible.
Automation & industry
Countless drive- and auxiliary motors of all performance classes are required in this area. CastCoils reduce sizes and energy costs.
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INTRODUCTION OF THE CAST COIL TECHNOLOGY
AND ITS ADVANTAGES

The use of CAST COILS enables electric machines with higher efficiency, higher power and torque density and a greater variety of variants with the same housing with copper coils for high performance and aluminum coils for lightweight solutions due to the higher utilization of installation space and flexible geometry design of the coils. Cast coils contribute to the reduction of energy consumption, e.g. in refrigeration plants by 10%, through higher efficiency and power density. Aluminum in particular enables lower energy consumption in production and recycling, 30% lower CO2 emissions and the use of CFC-free refrigerants in refrigeration and air conditioning technology, which accounts for around 15% of energy consumption in Germany. Furthermore, aluminum can also be used as a recycling material and thus enables closed-loop recycling for the powertrains of the future.

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What we offer

Cast-Coil_Euroguss_05
Cast Coil is honored with the International Die Casting Award!
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Cast-Coil_News_01
Cast Coil receives growth financing from "Stiftung Bienenelfe"
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Cast Coil | Technology transfer
Bienenelfe Foundation takes a strategic stake in Cast Coil​
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OUR VALUES
We strive to always provide the best results for our customers, no matter how big the challenge. Our goal is to do our best work in all areas every day.
OUR VALUES
We strive to always provide the best results for our customers, no matter how big the challenge. Our goal is to do our best work in all areas every day.
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About us

Cast Coil GmbH was notarized on July 18, 2023 in Münster as a spin-off of Fraunhofer IFAM and brings a highly innovative production process for manufacturing coils for electrical machines to the market. The core business is the transfer of technology into production and the licensing of the comprehensive patent portfolio. The young team currently consists of the three founders F.-J. Wöstmann, M. Heuser and Prof. M. Busse. All of them are significantly involved in the development of Cast Coils and are distinguished by their entrepreneurial activities and networks in addition to their scientific background. 

F.-J. Wöstmann Cast Coil Co-Founder
F.-J. Wöstmann
Co-Founder
M. Heuser Cast Coil Co-Founder
M. Heuser
Co-Founder
Prof. M. Busse Cast Coil Co-Founder
Prof. M. Busse
Co-Founder

Experience the future
of e-mobility