RWTH Aachen announces new component project with Röscher
The Chair of Production Engineering of E-Mobility Components (PEM) at RWTH Aachen University has started the “variTwist” project with its Berlin-based industrial partner Röscher GmbH. In the project, which is funded by the German Federal Ministry for Economic Affairs and Climate Protection, the partners are researching how to significantly reduce the high costs of certain processes in electric motor production.
To this end, a marketable, flexible tool system for interlocking flat copper conductors is to be developed in the next two years or so. The system should be adaptable to the different variant drivers in hairpin stator production and thus bring the advantage of a massive reduction in tool costs and delivery times, especially in prototype and small series production.
Currently, the researchers say, that one of the major cost drivers for electric vehicle manufacturing is “the process step of twisting in the production of hairpin stators for electric motors”. This process requires specialized tools with high demands for tolerance, accuracy, and strength. The expected investment for a tool set is currently in the range of 100,000 to 200,000 euros. Naturally, this is a considerable hurdle in terms of flexibility, especially for companies in the prototype design stage.
“The step of twisting is a particular cost driver in the production of hairpin stators for electric motors,” says PEM Director Professor Achim Kampker. “Here, special tools with high requirements for tolerance, accuracy, and strength are needed.”
Lately, the RWTH Aachen university has been involved in all kinds of e-mobility projects, ranging from a project focused on producing solid-state batteries, for which EU funds have been set aside, to monitoring processes for hydrogen tanks, both projects that have been announced this month. In May, RWTH and e.Volution presented an electric vehicle especially designed for a circular economy.
Update 26 January 2026
‘variTwist’ has been completed. According to PEM, the process station developed within the project enables the cost-effective realisation of a flexible twisting process with tooling costs below €1,000. Comparable equipment for conventional twisting systems has recently often been in the range of €100,000 to €200,000. According to the RWTH team, the system developed as part of ‘variTwist’ can be adapted to different variant drivers in hairpin stator production. Especially in prototype and small-series manufacturing, it is expected to offer not only a massive reduction in tooling costs but also a significant reduction in lead times.
rwth-aachen.de, rwth-aachen.de (variTwist), pem.rwth-aachen.de (update)
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