This is a Copper flat wire in typical hairpin geometry. It is approx. 30 cm high.

These hairpins are inserted into the stator stack - the stationary part of the motor.

The hairpins are pre-assembled in an assembly nest. The insertion process is limited by overlaps in the winding geometry.

To form a continuous winding scheme, the hairpin ends are electrically contacted.

Using a laser, the hairpin ends are partially melted and joined.

An optimal laser welding process is marked by homogenous weld geometries as well as minimal thermal input.

A very warm thank you to all the companies and institutes that made this publication possible.

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