{"id":1377,"date":"2023-09-03T14:13:35","date_gmt":"2023-09-03T14:13:35","guid":{"rendered":"https:\/\/novanta.com\/precision-manufacturing\/?post_type=novanta_tech_paper&#038;p=1377"},"modified":"2026-07-24T16:18:20","modified_gmt":"2026-07-24T16:18:20","slug":"unlocking-efficiency-in-electric-motors-the-power-of-hairpin-stripping","status":"publish","type":"novanta_tech_paper","link":"https:\/\/novanta.com\/precision-manufacturing\/resources\/whitepapers\/unlocking-efficiency-in-electric-motors-the-power-of-hairpin-stripping\/","title":{"rendered":"Unlocking Efficiency In Electric Motors: The Power Of Hairpin Stripping"},"content":{"rendered":"\n<p class=\"wp-block-paragraph\"><\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-technical-paper-overview\">Technical Paper Overview<\/h2>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-unlocking-electric-motor-efficiency-with-laser-hairpin-stripping-two-step-laser-stripping-not-single-laser-ablation-decides-hairpin-weld-quality\"><strong>Unlocking Electric Motor Efficiency with Laser Hairpin Stripping<\/strong><br><em>Two-step laser stripping, not single-laser ablation, decides hairpin weld quality.<\/em><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Hairpin stators are how high-efficiency electric motors get their efficiency. Rectangular copper wires with thicker copper fill factor than traditional round wire, organic insulation for safety. But the assembly hinges on welding the hairpin ends together \u2014 and a single micron of insulation residue on the copper produces weak welds, reduced motor efficiency, and inconsistent production yield.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">This technical paper from three Novanta authors documents a two-step laser process for hairpin stators: a 400W CO\u2082 laser (Novanta Firestar i401 at 10.6 \u00b5m) removes the bulk insulation, then a 200W nanosecond fiber laser removes the residual 1-2 \u00b5m layer \u2014 both running simultaneously through Novanta&#8217;s Chameleon dual-wavelength 3-axis scan head, achieving <1.0 second cycle times.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-key-takeaways-include\">Key takeaways include:<\/h2>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Why hairpin weld quality \u2014 and therefore motor efficiency \u2014 depends on complete removal of organic insulation (microns of residue fail the weld)<\/li>\n\n\n\n<li>How a two-laser combo (CO\u2082 for bulk + fiber for residue) outperforms any single-laser approach on speed AND quality<\/li>\n\n\n\n<li>When to choose 9.3 \u00b5m CO\u2082 over 10.6 \u00b5m: depends on insulation chemistry (PA, PE, PI), measured via ATR IR spectrometer<\/li>\n\n\n\n<li>What the Chameleon scan head enables: dual-wavelength processing through one 3-axis head with 75% field overlap<\/li>\n\n\n\n<li>A practical industry benchmark: <9 RFU fluorescence achieved on four hairpin designs in <1.0 second cycle<\/li>\n<\/ul>\n\n\n\n<p class=\"wp-block-paragraph\" id=\"h-\">Download the full technical paper for the ATR IR-spectrometer absorbance data across four insulation materials, the parameter sets for the CO\u2082 + fiber two-step process, and the Chameleon dual-wavelength scan-head architecture \u2014 before specifying a single-laser stripping system that doubles your cycle time and machine footprint.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>Technical Paper Overview Unlocking Electric Motor Efficiency with Laser Hairpin StrippingTwo-step laser stripping, not single-laser ablation, decides hairpin weld quality. Hairpin stators are how high-efficiency electric motors get their efficiency. Rectangular copper wires with thicker copper fill factor than traditional round wire, organic insulation for safety. But the assembly hinges on welding the hairpin ends [&hellip;]<\/p>\n","protected":false},"author":342,"featured_media":1158,"template":"","meta":{"_acf_changed":false,"card_thumbnail_id":0,"show_table_of_content":true},"class_list":["post-1377","novanta_tech_paper","type-novanta_tech_paper","status-publish","has-post-thumbnail","hentry"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v27.0 (Yoast SEO v27.4) - https:\/\/yoast.com\/product\/yoast-seo-premium-wordpress\/ -->\n<title>Hairpin Stripping for Electric Motor Efficiency | Novanta<\/title>\n<meta name=\"description\" content=\"Learn how laser ablation-based hairpin stripping improves electric motor efficiency, complementing battery electrode laser cutting in EV manufacturing.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" 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