BLDC Motor Core Lamination Stacks Manufacturer

As Sino, a top Chinese maker of very accurate motor core laminations, we know the important part our components play in the performance, efficiency, and long life of your BLDC motors. We promise to offer the newest lamination solutions that meet the many different and tough needs of motor makers in the car, airplane, factory, and electronics industries all over the world.

Introduction of BLDC Motor Core Lamination

Brushless DC (BLDC) motors are a key part of today’s electric and automatic systems. They have better efficiency, more power for their size, and better control than old-style brushed motors. The core lamination, which makes up the stator and rotor, is probably the most important part. It directly affects the motor’s magnetic power, how it handles heat, its noise and shaking, and how long it lasts. At Sino, we are experts in designing and making these complex parts. We know that one single solution doesn’t work for the special jobs they are used for today.

How Sino Delivers Excellence in BLDC Laminations

At Sino, our Steel Laminations are engineered to maximize these advantages:

Dramatically Slashed Eddy Current Losses

By effectively confining eddy currents, Sino’s precisely manufactured laminations ensure that more of your electrical input is converted into useful torque, not unwanted heat. We achieve this through careful selection of high-grade silicon steel, which inherently has higher electrical resistivity, and by ensuring the integrity and uniformity of the insulating coating between each sheet.

A Significant Boost in Motor Efficiency

Our Steel Laminations are not just thin; they are crafted to optimize the magnetic circuit. We work with materials that offer excellent permeability, allowing for strong magnetic fields, while our manufacturing processes ensure minimal air gaps and consistent stacking factors. This holistic approach to the BLDC motor core ensures that efficiency isn’t just a byproduct, but a design goal.

Cooler Operation, Longer Life

Reduced internal heat generation, thanks to effective lamination, puts less thermal stress on all motor components. Insulation lasts longer, bearings maintain their lubrication better, and the risk of permanent magnet degradation is minimized. This all adds up to increased reliability and a longer operational life for the motor.

Unlocking High-Frequency and High-Speed Potential

For applications like high-speed CNC spindles, medical drills, or advanced servo motors, Sino offers laminations down to 0.20mm or even 0.1mm. These ultra-thin options are critical for maintaining efficiency and preventing overheating in demanding high-frequency scenarios.

Mastering Lamination Thickness, Material, and Manufacturing

At Sino, we understand that the choice of material, the precision of the stamping process, the quality of the insulation, and the consistency of the stacking all play vital roles.

Thickness – A Delicate Balance

As we’ve seen, thinner is generally better for combating eddy currents. Sino offers a comprehensive range of Steel Lamination thicknesses, typically from 0.20mm up to 0.65mm, to suit diverse operational frequencies and cost targets. However, going too thin can increase manufacturing complexity and cost, and can slightly reduce the “stacking factor” (the proportion of actual iron in the core volume). Our engineers help clients navigate this trade-off to find the optimal solution.

Material Matters

We primarily utilize high-grade silicon steel (often called electrical steel). The addition of silicon (typically 1-4%) significantly increases the steel’s electrical resistivity – a key factor in reducing eddy currents – and also helps to minimize hysteresis losses (another type of core loss related to the magnetic domains reorienting). Different grades of silicon steel offer varying magnetic properties, loss characteristics, and mechanical strengths. Sino sources and processes these materials to exacting standards.

The Art of the Stack

Sino employs advanced stamping techniques to ensure clean edges and precise geometries, minimizing burrs that could breach insulation or create unwanted air gaps. Our insulation coatings are uniformly applied and cured to withstand the temperatures and mechanical stresses of motor assembly and operation. Whether it’s interlocking designs for mechanical integrity or precision welding for robust bldc stator lamination stacks, our focus is on creating a core that performs as a perfectly integrated unit.

Illustrative Impact of Lamination Choices

This table gives a conceptual idea of how lamination choices, like those Sino offers, can influence performance:

Lamination Thickness (mm)	Sino’s Grade / Typical Application Focus	Relative Eddy Current Loss Factor (Conceptual)	Key Benefit Sino Delivers
0.65	Sino Standard Grade / General Purpose Motors	Moderate (e.g., ~2.5x baseline)	Cost-effective solution for less demanding scenarios
0.50	Sino Performance Grade / Efficient Industrial Motors	Baseline (1x)	Excellent balance of performance and cost for many BLDCs
0.35	Sino High-Efficiency Grade / EVs, Premium Appliances	Lower (e.g., ~0.5x baseline)	Superior efficiency, reduced heat for demanding applications
0.20	Sino Ultra-High Frequency Grade / Servo, Aerospace	Very Low (e.g., ~0.15x baseline)	Minimizes losses at high PWM or rotational frequencies
Specialized <0.20mm	Sino Custom Solutions / Cutting-Edge R&D	Extremely Low	Pushing boundaries for niche, ultra-high-performance use

Disclaimer: Loss factors are illustrative and vary based on specific material grade, flux density, and operating frequency. Source: Adapted from general motor design principles and Sino’s internal characterization data.

Choosing the Right Materials for BLDC Core Laminations

Choosing the right material for the lamination is the basis for good performance in a BLDC motor core. Sino offers a wide variety of materials. Each one is picked and treated to get the right magnetic and physical features, made to fit what our customers need.

Electrical Steel Grades

The most common choice for BLDC motor laminations is still high-silicon electrical steels, which usually have 2–3.2% Si. This is because they have a good mix of low energy loss in the core and let magnetic fields pass through easily. We work with different types, including:

Non-Oriented Electrical Steel (NOES): These are the main, reliable materials. Their magnetic properties are the same in all directions, which is good for the spinning magnetic fields in BLDC motors. New and better NOES grades are always being improved to lower core energy loss and let magnetic fields pass through more easily.
Iron-Cobalt (Fe-Co) Alloys (e.g., Hiperco 50): For jobs that need very high performance, especially in aerospace, Fe-Co alloys are being used more and more. They offer a much higher top limit for magnetic fields (over 2.3 T) and less energy loss from swirling electric currents. This is especially important at high running speeds (>400 Hz). Even though they cost more, the better power for their size and higher efficiency they provide are very useful for tough jobs.

Advanced Soft Magnetic Materials: Amorphous and Nanocrystalline Steels

Sino is leading the way in using advanced soft magnetic materials in BLDC motor cores, because we see they can be extremely efficient, especially at high speeds.

Magnetic Properties: Nanocrystalline and amorphous electrical steels show much lower energy loss in the core compared to normal silicon steel. Nanocrystalline materials can have losses as low as 0.2–0.4 W/kg at 1.5 T, 50 Hz, while amorphous steels are usually around 0.5–0.7 W/kg. This is much better than the 2–3 W/kg for silicon steel in the same situation. This directly leads to a more efficient motor, especially with weak magnetic fields and at high running speeds (10–50 kHz, which is common in today’s BLDC systems). Both types of material also let magnetic fields pass through very easily at first (nanocrystalline: >10,000; amorphous: 2,000–4,000), which is very good for motor efficiency. A main downside is their lower top limit for magnetic fields. Amorphous steels usually have a Bs of 1.0–1.2 T, and nanocrystalline steels are around 1.2–1.3 T. This is lower than silicon steel (1.7–2.0 T). Because of this limit, we might need to change the design, like making the core bigger or using different ways of winding the wires, to get the turning force we need.
Insulation Coatings and Stopping Eddy Currents: For amorphous and nanocrystalline ribbons, special coatings like C5 and C6 are put on to create insulation between the layers. C6 is better at handling heat and loses less energy. These coatings are very important for stopping swirling electric currents (eddy currents), especially because the main material resists electricity well (amorphous: ~130 μΩ·cm; nanocrystalline: ~110 μΩ·cm). However, getting the coating even and making it stick are still hard to do at high production speeds.

Our BLDC Motor Core Lamination Products

How We Make BLDC Laminated Cores

The accuracy and quality of BLDC motor core laminations depend directly on the making process we use and how strictly we check for quality. At Sino, we use the most modern methods, mainly high-speed stamping and laser cutting, along with advanced finishing steps and strict rules for making sure everything is good quality.

Primary Making Methods

High-Speed Stamping

High-speed stamping is the way we like to make large amounts, because it’s super fast and saves a lot of money.

Production Amount: Our stamping lines can make things at a speed of over 600 pieces per minute. This lets us make tens of millions of laminations on each line every year.
Accuracy: Using top-quality tools from the best suppliers, we keep the size measurements very accurate (±0.01 mm) even when making huge numbers. We watch things closely to deal with tools wearing out and parts changing size with heat, to make sure the quality is always the same.
Material Use: Our special tools and smart layout plans use the material in the best way, getting an 80–90% success rate and making very little waste.
Best For: Stamping is best for standard silicon steel (0.2–0.5 mm) and for shapes that are simple or not too complex. However, the more complex the shape, the harder the tool is to make and the faster it wears out.

Laser Cutting

For making samples, test runs, or small numbers of special custom parts, laser cutting offers the best flexibility and accuracy.

Production Amount: Laser cutting is usually limited to 100–500 parts per hour, which makes financial sense for special jobs.
Accuracy: Laser cutting usually gets an accuracy of ±0.02 mm. Some fiber laser systems can even get down to ±0.01 mm for thin (≤0.5 mm) electrical steels.

Best For: Laser cutting can easily handle lamination thicknesses from 0.1 mm to 1.0 mm and can work with special materials (like cobalt-iron, amorphous alloys) and complex shapes (like segmented rotors, skewed slots) without changing any tools.

Special Making Methods

Sino also looks into and uses special methods for certain needs:

Fine Blanking: This method makes parts with almost no rough edges and very, very accurate measurements (±0.005 mm) for super-thin (≤0.2 mm) laminations, but each part costs more and it’s a slower process.

Sino's Commitment to Lamination Excellence

At Sino, we believe that manufacturing superior BLDC motor core lamination products goes beyond just stamping thin steel.

Precision Tooling: Our investment in high-precision dies and stamping presses ensures dimensional accuracy and repeatability, lamination after lamination. This minimizes inconsistencies that can affect magnetic flux paths and overall motor performance.
Coating Integrity: We utilize advanced insulation coating technologies and rigorous quality control to ensure complete, durable electrical separation between laminations. This is vital for realizing the full benefit of lamination.
Customization Capabilities: We understand that one size rarely fits all. Sino works closely with motor designers and manufacturers to provide custom lamination profiles, slot designs (including skewed slots to reduce cogging torque), and specific material grades tailored to their unique application requirements.
Interlocking and Stacking Innovations: Whether it’s robust interlocking features that eliminate the need for welding in some designs, or precision robotic welding for maximum structural integrity in high-stress bldc stator lamination stacks, our assembly techniques are optimized for performance and manufacturability.

Where Sino's Steel Laminations Make the Difference

The impact of high-quality brushless motor laminations is felt across a vast spectrum of industries:

Why Sino is the Clear Choice

When you’re designing or manufacturing BLDC motors, the quality of the core laminations is not a place to compromise. Partnering with Sino for your Steel Lamination needs brings distinct advantages:

Deep Expertise

We live and breathe laminations. Our team understands the nuances of magnetic materials, stamping technology, and the specific demands of BLDC motor core and bldc stator lamination design.

Unwavering Commitment to Quality

From raw material inspection to final stack verification, quality is embedded in every Sino process.

Collaborative Approach

We see ourselves as more than just suppliers; we are partners in your success. We work with you to understand your performance goals and provide laminations that help you achieve them.

Reliability and Consistency

You can count on Sino to deliver high-quality laminations, on time, every time, allowing you to streamline your own production.

The Foundation of Future Motion: Built with Sino Laminations

The humble BLDC motor core lamination might not always grab the headlines, but it’s undeniably a foundational element of modern motion technology. By diligently controlling those invisible eddy currents, these precisely engineered steel sheets unlock efficiency, power, and reliability.

At Sino, we’re proud to craft the Steel Laminations that empower engineers and innovators to build the next generation of high-performance BLDC motors. If you’re ready to elevate your motor designs and ensure your products operate at their absolute best, let’s talk.

Get in Touch with Us Today

Discover how Sino’s dedication to lamination excellence can be your competitive advantage.

Note: To speed up your project, you can label Lamination Stacks with details such as tolerance, material, surface finish, whether or not oxidized insulation is required, quantity, and more.

BLDC Motor Core Lamination Stacks Manufacturer

Introduction of BLDC Motor Core Lamination

How Sino Delivers Excellence in BLDC Laminations