Here you will find answers to frequently asked questions about Cast Coils.
What are Cast Coils?
Cast Coils are innovative windings for electric machines produced by casting copper or aluminium instead of using conventional wire windings.
What are the main advantages of Cast Coils compared to conventional copper windings?
They provide higher efficiency, up to 100 % more continuous torque, lower weight (up to 40 % lighter with aluminium) and a slot fill factor of up to 90 % instead of 55 %.
Their geometry ensures more homogeneous heat distribution and improved heat dissipation.
What is the difference between copper and aluminium cast windings?
Copper: maximum performance and highest torque density.
Aluminium: up to 40 % lighter, 30 % lower CO₂ emissions and reduced energy consumption in production and recycling.
How do Cast Coils contribute to energy savings?
Thanks to their excellent thermal and electrical properties, Cast Coils can reduce energy consumption in applications such as cooling and air conditioning by up to 10 %.
Can Cast Coils be recycled?
Yes. Aluminium in particular allows for closed-loop recycling and supports sustainable drive systems of the future.
Which manufacturing processes are used?
Cast Coils can be produced by die casting, low-pressure casting, investment casting or sand casting.
Who is Cast Coil GmbH?
Cast Coil GmbH was founded in 2023 in Münster as a spin-off of Fraunhofer IFAM. The company focuses on technology transfer, licensing, and the production of prototypes for cast windings as well as motor design and development.