Powerful Solutions for Electric Drives

Hairpins are bent parts made of insulated, enameled copper wire. They are used in the modern electric motors found in electric cars, hybrid vehicles, and e-bikes, where they replace the wound inductor coils that are part of conventional stators. Hairpin motors improve the power-to-weight ratio due to the packing density of the profile material.

WAFIOS offers state-of-the-art bending technology for producing hairpins, covering everything from small batches up to high volumes.

Machine comparison FSE & F Series

  • Modular, customized equipment options
  • Reduced costs due to modular design, energy efficiency and optimized tooling times
  • Machine takes up little space, enabling optimum factory planning and plant logistics
  • Economic output due to high availability
  • Flexibility thanks to space-saving machine concept

Please select wire diameter [mm]

0.12 mm6.94 mm14 mm

F 08 from 0.12
to 0.8 mm

Wire diameter 0.12 - 0.8 mm
Wire diameter at Wm 6 or Rm max. 2,600 N/mm² 0.12 - 0.6 mm
Wire diameter at Wm 4 or Rm max. 2,300 N/mm² 0.6 - 0.8 mm
Outer spring diameter max. 20 mm
Coiling direction right and left
Feed speed max. 160 m/min

F 12 from 0.2
to 1.2 mm

Wire diameter 0.12 - 0.8 mm
Wire diameter at Wm 4 or Rm max. 2,500 N/mm² 0.2 - 1.1 mm
Wire diameter at Wm 5 or Rm max. 1,800 N/mm² 1.1 - 1.2 mm
Outer spring diameter max. 20 mm
Coiling direction rechts und links
Feed speed max. 160 m/min

F 18 from 0.35
to 1.8 mm

Wire diameter 0.35 - 1.8 mm
Wire diameter at Wm 4 or Rm max. 2,300 N/mm² 0.35 - 1.6 mm
Wire diameter at Wm 4 or Rm max. 1,900 N/mm² 1.6 - 1.8 mm
Outer spring diameter max. 40 mm
Coiling direction rechts und links
Feed speed max. 140 m/min

FSE 143 from 6.1
to 14 mm

Wire diameter 6.1 - 14 mm
Wire strength Rm = 2,000 N/mm²
Spring index ≥4
Outer spring diameter max. 240 mm
Coiling direction Right
Feed speed max. 70 m/min

F 30 from 0.7
to 3 mm

Wire diameter 0.7 - 3 mm
Wire diameter at Wm 4 or Rm max. 2,000 N/mm² 0.7 - 2.5 mm
Wire diameter at Wm 6 or Rm max. 1,800 N/mm² 2.5 - 3 mm
Outer spring diameter max. 65 mm
Coiling direction Right, left as option
Feed speed max. 135 m/min

F 4 from 1.5
to 4.5 mm

Wire diameter 1.5 - 4.5 mm
Wire diameter at Rm max. 2,000 N/mm² 1.5 - 4 mm
Wire diameter with Rm max. 1,800 N/mm² 1.5 - 4.5 mm
Outer spring diameter max. 100 mm
Coiling direction right and left
Feed speed max. 100 m/min

F 6 from 2.6
to 7 mm

Wire diameter 2.6 - 7 mm
Wire diameter at Rm max. 2,000 N/mm² 2.1 - 6 mm
Wire diameter with Rm max. 1,800 N/mm² 2.1 - 7 mm
Outer spring diameter max. 130 mm
Coiling direction right and left
Feed speed max. 100 m/min

F 08

  • Fully fledged compression spring coiler as standard version, modular expansion options
  • Optimum unit costs in compression spring production
  • High availability thanks to reliable and proven machine control plus easy-to-maintain design
  • High-performance development with extended range of applications
  • Precision thanks to the latest measuring and control technology
  • Shorter set-up time and greater operating convenience
F08_-400x400pixel_300ppi.png

Further information

L_AHP1-AHP6_Folder_V1-2_DE.pdf
AHP 1 - AHP 6 (German)

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(PDF, 428 KB)
L_AHP_Folder-AHP-Residual-Weight-Detection_V1-1_DE.pdf
AHP Residual-Weight-Detection (German)

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(PDF, 125 KB)
L_AHT-Series_Folder-AHT-Series_V1-1_DE.pdf
AHT-Series (German)

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(PDF, 101 KB)
L_FUL16-FUL166_V1-1_DE.pdf
FUL 16plus - FUL 166 (German)

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(PDF, 1 MB)
L_FUL175_Folder-FUL175_V1-1_ALL.pdf
FUL 175 (German)

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(PDF, 94 KB)
L_FUL226_V1-2_DE.pdf
FUL 226 (German)

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(PDF, 590 KB)
L_FUL226_V1-2_EN.pdf
FUL 226 (All)

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(PDF, 590 KB)
L_FUL_iQopticut_V1-1_DE.pdf
iQopticut (German)

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(PDF, 1 MB)
L_GH46_Pay-Off_V1-1__DE.pdf
GH 46 (German)

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(PDF, 64 KB)
L_H3-H3V-H7-Folder_DE.pdf
H3 - H3V - H7 (German)

Download
(PDF, 120 KB)
L_TC_TC-Tooling-Solutions-Spring-Coilers_V1-2_DE.pdf
Werkzeuglösungen für große Federwindemaschinen (German)

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(PDF, 171 KB)
L_TC_TC-W46-Cutting-Mandrels-and-Cutters_V1-2_DE.pdf
Abschneidedorne aus Werkstoff W46 (German)

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(PDF, 2 MB)
L_TC_Wafios-Torsion-Cut_V1-2_DE.pdf
WAFIOS Torsion Cut Werkzeugsystem (German)

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(PDF, 591 KB)
L_AHP1-AHP6_Folder_V1-2_EN.pdf
AHP 1 - AHP 6 (All)

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(PDF, 426 KB)
L_AHT-Series_Folder-AHT-Series_V1-1_EN.pdf
AHT-Series (All)

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(PDF, 102 KB)
L_F-Series_Folder-F-Series_V1-1_DE.pdf
F-Series (German)

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(PDF, 776 KB)
L_F-Series_Folder-F-Series_V1-1_EN.pdf
F-Series (All)

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(PDF, 736 KB)
L_F30_Folder-F30_V1-1_DE.pdf
F30 (German)

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(PDF, 298 KB)
L_F30_Folder-F30_V1-1_EN.pdf
F30 (All)

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(PDF, 297 KB)
L_FSE143_Folder-FSE143_V1-1_DE.pdf
FSE 143 (German)

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(PDF, 348 KB)
L_FSE143_Folder-FSE143_V1-1_EN.pdf
FSE 143 (All)

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(PDF, 346 KB)
L_FUL-FSE_iQautopitch_V1-4_DE.pdf
iQautopitch (German)

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(PDF, 1 MB)
L_FUL-FSE_iQautopitch_V1-4_EN.pdf
iQautopitch (All)

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(PDF, 1 MB)
L_FUL-FSE_iQspring2FUL_V1-2_DE.pdf
iQspring2FUL (German)

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(PDF, 857 KB)
L_FUL-FSE_iQspring2FUL_V1-2_EN.pdf
iQspring2FUL (All)

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(PDF, 852 KB)
L_FUL-F_iQbestspeed_V1-3_DE.pdf
iQbestspeed (German)

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(PDF, 1 MB)
L_FUL-F_iQbestspeed_V1-3_EN.pdf
iQbestspeed (All)

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(PDF, 1 MB)
L_FUL16-FUL166_V1-1_EN.pdf
FUL 16plus - FUL 166 (All)

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(PDF, 1 MB)
L_FUL26_-FUL36__V1-2_DE.pdf
FUL 26 - FUL 36 (German)

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(PDF, 158 KB)
L_FUL26_-FUL36__V1-2_EN.pdf
FUL 26 - FUL 36 (All)

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(PDF, 158 KB)
L_FUL166_Folder-FUL166_V1-1_DE.pdf
FUL 166 (German)

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(PDF, 259 KB)
L_FUL166_Folder-FUL166_V1-1_EN.pdf
FUL 166 (All)

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(PDF, 258 KB)
L_FUL175_Folder-FUL175_V1-1_ALL.pdf
FUL 175 (All)

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(PDF, 94 KB)
L_FUL183_Folder-FUL183_V1-1_DE.pdf
FUL 183 (German)

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(PDF, 66 KB)
L_FUL183_Folder-FUL183_V1-1_EN.pdf
FUL 183 (All)

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(PDF, 65 KB)
L_FUL203_Folder-FUL203_V1-1_DE.pdf
FUL 203 (German)

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(PDF, 66 KB)
L_FUL203_Folder-FUL203_V1-1_EN.pdf
FUL 203 (All)

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(PDF, 65 KB)
L_FUL226_V1-2_DE.pdf
FUL 226 (German)

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(PDF, 590 KB)
L_FUL226_V1-2_EN.pdf
FUL 226 (All)

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(PDF, 590 KB)
L_FUL_iQcontrol_V1-4_DE.pdf
iQcontrol (German)

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(PDF, 920 KB)
L_FUL_iQcontrol_V1-4_EN.pdf
iQcontrol (All)

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(PDF, 918 KB)
L_FUL_iQopticut_V1-1_EN.pdf
iQopticut (All)

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(PDF, 1 MB)
L_GH46_Pay-Off_V1-1_EN.pdf
GH46 (All)

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(PDF, 64 KB)
L_GH46_Pay-Off_V1-1__DE.pdf
GH 46 (German)

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(PDF, 64 KB)
L_H3-H3V-H7-Folder_DE.pdf
H3 - H3V - H7 (German)

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(PDF, 120 KB)
L_H3-H3V-H7_Folder_EN.pdf
H3 - H3V - H7 (All)

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(PDF, 120 KB)
L_TC_Coating-Tooling_V1-1_DE.pdf
Probleme bei der Verarbeitung von Edelstahl? (German)

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(PDF, 87 KB)
L_TC_Coating-Tooling_V1-1_EN.pdf
Problems in the processing of stainless steel? (All)

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(PDF, 87 KB)
L_TC_Coiling-Pins-with-Insert_V1-2_DE.pdf
Windestifte mit Einsatz – Die flexible Alternative (German)

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(PDF, 188 KB)
L_TC_Coiling-Pins-with-Insert_V1-2_EN.pdf
Coiling Pins with Insert - The Flexible Alternative (All)

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(PDF, 230 KB)
L_TC_Coiling-roller-with-holder_V1-2_EN.pdf
Coiling Roller with Mounting Fixture – The Alternative to Stationary Coiling Tools (All)

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(PDF, 190 KB)
L_TC_Cutting-Mandrel-W04_V1-2_DE.pdf
Abschneidedorne und –messer aus Werkstoff W04 (German)

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(PDF, 416 KB)
L_TC_Cutting-Mandrel-W04_V1-2_EN.pdf
Cutting Mandrels and Cutters Made of W04 Material (All)

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(PDF, 416 KB)
L_TC_Cutting-Mandrel-W46_V1-2_DE.pdf
Abschneidedorne und –messer aus Werkstoff W04 (German)

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(PDF, 364 KB)
L_TC_Cutting-Mandrel-W46_V1-2_EN.pdf
Cutting Mandrels Made of W46 Material (All)

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(PDF, 364 KB)
L_TC_Cutting-Tool-Holder-with-Insert_V1-3_DE.pdf
Messerhalter mit Einsatz – Rotationsschnitt (German)

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(PDF, 251 KB)
L_TC_Cutting-Tool-Holder-with-Insert_V1-3_EN.pdf
Cutting Tool Holder with Insert – Rotary Cut (All)

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(PDF, 250 KB)
L_TC_Feed-Rollers-W01-W03_V1-1_DE.pdf
Einzugswalzen aus Werkstoff W01 und W03 – Auswahl mit System (German)

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(PDF, 124 KB)
L_TC_Feed-Rollers-W01-W03_V1-1_EN.pdf
Feed rollers made of W01 and W03 material – system-based selection (All)

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(PDF, 123 KB)
L_TC_PKD_Coiling_Pins_V01-1_DE.pdf
Windestifte mit PKD – Edelstahldraht wirtschaftlich verarbeite (German)

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(PDF, 985 KB)
L_TC_PKD_Coiling_Pins_V01-1_EN.pdf
Coiling Pins with PCD Insert - Processing Stainless Steel Wire Economically (All)

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(PDF, 978 KB)
L_TC_Regrinding-cutting-mandrels_V1-2_DE.pdf
RE-GRINDING lohnt sich- bis zu 70% Kostenersparnis ihr Nachschleifservice für Abschneidedorne (German)

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(PDF, 282 KB)
L_TC_Regrinding-cutting-mandrels_V1-2_EN.pdf
RE-GRINDING pays off - Cost savings of up to 70% Your regrinding service for cutting mandrels (All)

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(PDF, 278 KB)
L_TC_RotaryRollerWireGuide_V1-1_DE.pdf
Drehbarer Rollendrahtführung – Optimiert für die Verarbeitung von Profildraht (German)

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(PDF, 751 KB)
L_TC_RotaryRollerWireGuide_V1-1_EN.pdf
Rotary Roller Wire Guide - Optimized for Processing Profiled Wire (All)

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(PDF, 750 KB)
L_TC_Rotatable-Coiling-Insert-RCI_V1-2_DE.pdf
Drehbarer Windeeinsatz – RCI (Rotable Coiling Insert) (German)

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(PDF, 505 KB)
L_TC_Rotatable-Coiling-Insert-RCI_V1-2_EN.pdf
Rotatable-Coiling-Insert-RCI (All)

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(PDF, 501 KB)
L_TC_TC-Tooling-Solutions-Spring-Coilers_V1-2_DE.pdf
Werkzeuglösungen für große Federwindemaschinen (German)

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(PDF, 171 KB)
L_TC_TC-Tooling-Solutions-Spring-Coilers_V1-2_EN.pdf
Tool solutions for large spring coiling machines (All)

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(PDF, 188 KB)
L_TC_TC-W04-Cutting-Mandrels-and-Cutters_V1-2_DE.pdf
Abschneidedorne und –messer aus Werkstoff W04 (German)

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(PDF, 2 MB)
L_TC_TC-W04-Cutting-Mandrels-and-Cutters_V1-2_EN.pdf
Cutting Mandrels and Cutters Made of W04 Material (All)

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(PDF, 2 MB)
L_TC_TC-W46-Cutting-Mandrels-and-Cutters_V1-2_EN.pdf
Cutting Mandrels Made of W46 Material (All)

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(PDF, 2 MB)
L_TC_Wafios-Torsion-Cut_V1-2_DE.pdf
WAFIOS Torsion Cut Werkzeugsystem (German)

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(PDF, 591 KB)
L_TC_Wafios-Torsion-Cut_V1-2_EN.pdf
WAFIOS Torsion Cut Tool System (All)

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(PDF, 610 KB)
L_TC_Winding-roller-with-holder_V1-2_DE.pdf
Winderolle mit Halter – die Alternative zu starren Windewerkzeugen (German)

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(PDF, 190 KB)
L_TC_Winding-roller-with-holder_V1-2_EN.pdf
Coiling Roller with Mounting Fixture – The Alternative to Stationary Coiling Tools (All)

Download
(PDF, 190 KB)
L_FUL16plus_DE_V1-1.pdf
FUL 16+ (German)

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(PDF, 3 MB)
L_FUL16plus_EN_V1-1.pdf
FUL 16+ (All)

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(PDF, 3 MB)
L_AHF50-150_V1-2_DE_HQ.pdf
AHF 50, AHF 150 (German)

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(PDF, 1 MB)
L_AHF50-150_V1-2_EN_HQ.pdf
AHF 50, AHF 150 (All)

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(PDF, 1 MB)