Contact Sales & After-Sales Service

Contact & Quotation

  • Inquire: Call 0086-755-23203480, or reach out via the form below/your sales contact to discuss our design, manufacturing, and assembly capabilities.
  • Quote: Email your PCB files to Sales@pcbsync.com (Preferred for large files) or submit online. We will contact you promptly. Please ensure your email is correct.
Drag & Drop Files, Choose Files to Upload You can upload up to 3 files.

Notes:
For PCB fabrication, we require PCB design file in Gerber RS-274X format (most preferred), *.PCB/DDB (Protel, inform your program version) format or *.BRD (Eagle) format. For PCB assembly, we require PCB design file in above mentioned format, drilling file and BOM. Click to download BOM template To avoid file missing, please include all files into one folder and compress it into .zip or .rar format.

PCB Stators | Axial-Flux Motor PCB Stator Design & Manufacturing — PCBSync
Axial-Flux Motor Technology

PCB stators —
engineered, then built right.

Printed-circuit stators turn copper traces into motor windings for axial-flux machines. PCBSync helps stator engineers and brands get the design right — heavy copper, the right layer count and material — and manufactures it from prototype to volume.

Request a stator quote Discuss your design
Heavy copper Up to 56 layers DFM & co-design Prototype to volume
PCB stators of different diameters for axial-flux motors, manufactured by PCBSync
Multi-size PCB stators — axial-flux windings
Up to 12 ozHeavy copper
Up to 56Layers
FR-4 · PIMetal-core & more
±7%Controlled thickness
100%Electrically tested
What is a PCB stator?

Copper traces, not wound wire

A PCB stator replaces the hand-wound copper of a conventional motor with copper windings etched directly onto one or more PCB layers, laid out in precise radial patterns. It is the heart of an axial-flux permanent-magnet motor, sitting between two magnet rotors so that magnetic flux passes axially through the printed windings.

Because the windings are photo-etched and stacked, every stator is identical, ultra-thin and perfectly balanced — eliminating end-windings, cutting weight, and giving designers freedom to shape the winding for torque, efficiency or low cogging.

The result is a motor that is lighter, flatter and more repeatable than wire-wound designs — increasingly the choice for drones, robotics, e-mobility and high-efficiency industrial machines.

Axial-fluxStator between two magnet rotors
Layered copperMore layers = more turns & torque
Heavy copperHigher current density, less heat
RepeatableEtched, balanced, identical units
Why PCB stators

Advantages over wire-wound stators

For the right application, a printed stator outperforms a wound one on weight, precision and manufacturability.

Precision & repeatability

Photo-etched windings are identical unit-to-unit — no hand-winding variance, tight phase balance and consistent performance.

Light & ultra-thin

No bobbins or end-windings means a flatter, lighter stator — ideal where power density and packaging matter.

Higher efficiency

Eliminating end-turn copper cuts resistive losses, while precise geometry reduces eddy and cogging effects.

Balance & high speed

Flat, symmetric copper gives excellent mechanical balance for low vibration and high-RPM operation.

Thermal performance

Broad flat conductors and thermal vias — plus metal-core or heavy-copper options — spread heat efficiently.

Scalable manufacturing

No winding labor — stators are produced like any PCB, so prototypes and volume use the same repeatable process.

Stator types & applications

Where PCB stators are used

From sub-watt sensors to high-torque traction motors — printed stators scale across power levels and industries.

Drones & eVTOLHigh power-to-weight
Robotics & cobotsCompact, precise torque
E-mobilityE-bikes, scooters
EV & tractionHigh-torque drive
Fans, HVAC & pumpsQuiet, efficient
Industrial automationServo & spindle
GeneratorsWind & micro-gen
Resolvers & sensorsPrinted coils
Layers for different stator uses

How many layers does your stator need?

Layer count and copper weight set the available turns and current — and therefore torque. Use this as a starting point, then refine with our engineers for your torque, current and airgap targets.

Application / power levelTypical layersCopper weightWhat drives it
Sensors, resolvers, micro-fans2 – 41 – 2 ozLow current; size & cost priority
Drones, compact BLDC, hobby4 – 82 – 4 ozHigh power-to-weight, moderate current
Robotics, cobots, e-bikes / scooters8 – 162 – 6 ozMore turns for torque; thermal headroom
EV traction, industrial, high-torque16 – 30+Heavy copperHigh current density & continuous torque
High-power machines & generators20 – 56Heavy copperMaximum copper cross-section

Guidance only — optimal layer count depends on your torque/speed curve, bus voltage, phase configuration and mechanical airgap. We help you balance turns, copper weight and thickness for your target. See our multilayer PCB and heavy-copper PCB capabilities.

Materials guide

Choosing the right base material

Operating temperature and power density drive material choice. Heavier loads and hotter environments move you up the stack.

MaterialBest forKey strength
Standard FR-4 (Tg 140)General & cost-sensitive statorsProven, economical, widely available
High-Tg FR-4 (Tg 170+)Higher power & temperatureBetter thermal endurance & reliability
PolyimideHigh-temp & flexible statorsWithstands harsh, high-temperature use
Aluminium / metal-coreThermally demanding, high-powerSuperior heat dissipation
Ceramic-filled / high-thermalStable, high-thermal designsHigh conductivity & dimensional stability
Rogers / hydrocarbonHigh-speed / specialty drivesStable dielectric for fast switching

Need help matching a material to your duty cycle and temperature class? Talk to us — and explore metal-core PCB and flex / polyimide options.

PCB stator design tips

Get the most from your printed windings

Six considerations that decide whether a stator hits its torque, thermal and reliability targets.

Copper weight drives torque

Heavier copper lowers winding resistance and raises current density — more torque, less heating. Balance it against the trace and space your copper weight allows.

Layers set your turns

Stack and interconnect layers to build turns per phase. Series connections raise back-EMF/torque; parallel paths raise current capacity — choose for your KV and bus voltage.

Symmetry & low cogging

Keep phases geometrically symmetric and resistance-matched for smooth torque, low cogging and minimal circulating currents.

Size your vias for current

Layer transitions carry full phase current — use via arrays, larger or filled vias to handle the load and ensure long-term reliability.

Manage the heat

Use thermal vias, broad copper pours and — for high power — high-Tg, metal-core or ceramic bases to pull heat out of the windings.

Flatness & airgap

A flat, rigid stator keeps the airgap tight and uniform — directly improving flux and torque. Control board thickness, warp and mounting.

Manufacturing & co-design

Built by a heavy-copper, high-layer specialist

PCB stators push two limits at once — many layers and thick copper. PCBSync builds both on an in-house line, with the registration, plating and flatness control that printed windings demand.

  • Heavy copper to 12 oz with controlled etch for accurate winding cross-section.
  • Up to 56 layers with X-ray registration for accurate layer-to-layer alignment.
  • FR-4, high-Tg, polyimide, metal-core and specialty materials for any duty cycle.
  • AOI, 100% electrical test and lab verification — see our PCB laboratory.
  • Engineering & DFM support, NDA on request — we co-develop, not just fabricate.
PCBSync heavy-copper PCB plating line for stator manufacturing Heavy-copper plating line
Layers1 – 56High-turn stator stacks
Copper weight0.5 – 12 ozStandard to heavy copper
Base materialsFR-4 · high-Tg · PIMetal-core, ceramic, Rogers
Thickness control± 7%For flat, tight-airgap stators
Surface finishENIG · OSP · ImAgHard gold for contacts
VolumeProto → massSame line, same data
How we work with you

From design intent to production stators

1

Share your design

Send Gerbers or your requirements — torque, current, size, voltage and temperature class.

2

Feasibility & DFM

We review copper weight, layers, vias and material, flag risks and quote — usually within 24 hours.

3

Prototype & test

Quick-turn stator prototypes with AOI and 100% electrical test for your bench validation.

4

Scale to production

The same proven data and process moves straight into volume, with full traceability.

Start your PCB stator project

Talk to a PCB stator engineer

Send your design or requirements and we'll reply with feasibility, a recommended stackup and a quote — usually within 24 hours. NDA on request.

  • Gerbers or a spec — torque, current, RPM, bus voltage.
  • Size & temperature class — diameter, thickness, environment.
  • Quantity — prototype, pilot or production.

PCB stator inquiry

Reply within 24 hours · DFM included · NDA on request
or
Upload your design files →
Submitting opens your email app with the details prefilled. Files are attached on the upload page.
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Related capabilities

Heavy Copper PCBUp to 12 oz copper Multilayer PCBUp to 56 layers Metal-Core PCBThermal management Rigid PCB CapabilitiesFull fab spec PCB PrototypingQuick-turn stators All CapabilitiesPCB & assembly
Answers

PCB stators — FAQ

A PCB stator replaces traditional wound copper windings with copper traces etched onto one or more PCB layers, arranged in radial patterns to form the motor windings. It is used in axial-flux permanent-magnet motors, where the printed stator sits between two magnet rotors and flux passes axially through it.

It depends on torque, current and space. Sensors and small fans may use 2–4 layers; drones and compact BLDC motors 4–8; robotics and e-mobility 8–16; and high-torque, EV or industrial machines 16 to 30+ layers, often with heavy copper. More layers add turns and torque at the cost of thickness and price.

FR-4 suits general and cost-sensitive designs; high-Tg FR-4 handles higher power and temperature; polyimide is used for high-temperature and flexible stators; and aluminium / metal-core or ceramic-filled laminates help with thermal dissipation in high-power motors. Material choice is driven mainly by operating temperature and power density.

Yes. Heavy copper is central to high-torque PCB stators because it lowers winding resistance and raises current density. PCBSync builds heavy-copper, high-layer-count stators and will advise on the achievable trace and space for your chosen copper weight — see our heavy-copper PCB page.

Yes. Our engineers provide DFM feedback on winding patterns, via strategy, copper weight and stackup, build quick-turn prototypes, and scale the same design to production. Send your files or requirements for a feasibility review and quote, usually within 24 hours. NDA on request.

Let's build your PCB stator.

From a first prototype to volume production — partner with a heavy-copper, high-layer-count manufacturer that helps you get the design right.

Request a stator quote Talk to an engineer

Contact Sales & After-Sales Service

Contact & Quotation

  • Inquire: Call 0086-755-23203480, or reach out via the form below/your sales contact to discuss our design, manufacturing, and assembly capabilities.

  • Quote: Email your PCB files to Sales@pcbsync.com (Preferred for large files) or submit online. We will contact you promptly. Please ensure your email is correct.

Drag & Drop Files, Choose Files to Upload You can upload up to 3 files.

Notes:
For PCB fabrication, we require PCB design file in Gerber RS-274X format (most preferred), *.PCB/DDB (Protel, inform your program version) format or *.BRD (Eagle) format. For PCB assembly, we require PCB design file in above mentioned format, drilling file and BOM. Click to download BOM template To avoid file missing, please include all files into one folder and compress it into .zip or .rar format.