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What is a Hairpin Winding & Hairpin Winding Machine

Honest| 2024-02-15|Return

What is a hairpin winding?

Hairpin winding refers to a specific technique used in the manufacturing of electric motors, particularly for the stators in brushless motors. The technique involves bending wires into a hairpin or “U” shape and then inserting these hairpins into the slots of the motor’s stator core. Once in place, the ends of the hairpins are electrically connected, either by welding or using other forms of connection, to form the continuous winding necessary for the motor’s operation.

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The hairpin winding technique offers several advantages over traditional winding methods:

A. High Efficiency: hairpin winding has a short end-turn length, which reduces resistive losses and can improve the motor’s overall efficiency.

B. High Slot Fill: the shape and packing of hairpin winding allow for a higher fill factor in the stator slots, meaning more copper can be placed in the same space, which can increase the motor’s torque output.

C. Automated production: the process of inserting and connecting hairpin winding can be highly automated, leading to increased production speed and consistency, as well as reduced labor costs.

D. Reduced Mechanical Stress: hairpins are more robust than circular wires and are less susceptible to vibration and mechanical stress. This leads to improved reliability and longer lifespan.

E. Simplified Assembly: hairpins can be performed and inserted into the stator slots quickly and easily, which can reduce assembly time and cost.

F. Improved cooling: the flat shape of hairpins improves heat transfer from the winding to the stator core, allowing for better cooling and higher power density.


The hairpin winding is becoming increasingly popular in the automotive industry, especially for electric vehicle motors. The improved efficiency and power density of hairpin motors can help to increase the range and performance of electric vehicles.

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The market forecast of the hairpin winding

According to the relevant report, the global hairpin winding market size is expected to reach 1 billion dollars in 2024, a year-on-year increase of 20%. Hairpin winding has the advantages of small size, lightweight, and high power density, and has a broad application prospect in the fields of new energy vehicles and industrial motors.


The global hairpin winding market in 2024 will show the following characteristics:

A. The new energy vehicle market will be the main driving force for the growth of hairpin winding;

B. The industrial motor market will maintain steady growth;

C. Other areas will show faster growth.

The global hairpin winding market will show the following regional distribution characteristics:


China Market

The Chinese market will maintain its leading position.

China is the largest market for new energy vehicles and a major application area for hairpin winding in the world. With the rapid development of China’s new energy vehicle market, the demand for hairpin winding will maintain strong growth. It is expected that China’s hairpin winding market will reach 450 million dollars in 2024, a year-on-year increase of 25%.


U. S. Market

The U.S. market will maintain growth momentum.

The U.S. government has also introduced several policies to support the development of new energy vehicles, which will provide a good policy environment for the hairpin winding market. In addition, the growing demand for high-performance hairpin winding in the U.S. market is also providing impetus for market growth. The U.S. hairpin winding market is expected to reach 250 million dollars in 2024, a year-on-year increase of 18%.


European Market

The European market will usher in new development opportunities.

The European government's support for new energy vehicles is increasing, which will provide a broad market space for the hairpin winding market. In addition, the European market has higher safety and reliability requirements for hairpin winding, which will promote hairpin winding enterprises to continuously improve product technology and quality. The European hairpin winding market size is expected to reach 200 million dollars in 2024, with a year-on-year growth of 15%.


What’s more, the markets in Asian countries and regions such as Japan and South Korea will also maintain growth momentum. The new energy vehicle markets in these countries and regions will also develop rapidly, and the demand for hairpin winding will also continue to grow. It is expected that the hairpin winding market size in Japan, South Korea, and other Asian countries and regions will reach 150 million dollars in 2024, a year-on-year increase of 10%.


In a word, the global hairpin winding market will show a steady rise in 2024. With the development of new energy vehicles, industrial motors, and other fields, the hairpin winding will usher in a broader development space.

The key trends in the hairpin winding market include:

A. High power density and high-reliability products will become the mainstream of the market.

B. The integration of hairpin winding and new technologies will become the future development direction.


The advantages of HONEST HLS in hairpin winding machine:

A. There are customer cases of mature winding machines, which have been successfully produced in the customer’s factory;

B. The equipment solution design team has rich experience in the motor industry. Some senior engineers have more than 10 years of experience in the motor industry, and the design is more in line with customer needs;

C. The equipment will prompt various misoperations and bad status in real-time;

D. When the equipment is abnormal, an abnormal alarm will be displayed on the screen to prompt the abnormal location to facilitate manual operation.

E. The equipment can achieve precision wiring, no wire damage, and can reserve wire ends and tails.

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