Current projects

DER Hairpin: Accelerating the UK E-machine Preformed Winding Chain

Project Overview

The aim of this industrial research is to develop flexible, scalable and automated manufacturing processes for next-generation hairpin windings (e.g. laminated and roebel type) to accelerate the related UK supply chain in used in high-performance electric machines, well beyond the international competition.

MDL will carry out:

  • A full multi-physics analysis of hairpin winding.
  • Full 3D design capability of pre-formed windings.
  • Including manufacturability and manufacturing constraints/processes, validated by pilot/test results.
  • Multi-physics winding design and impact on motor performance.

  • Timeline: April 2020 — June 2021
  • Funding: Innovate UK, Driving the electric revolution: accelerated supply chain development, strand 1

Project Partners
  • Motor Design Ltd
  • Belcan
  • GKN Automotive
  • Cummins
  • The University of Nottingham.


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