As the name suggests, the biggest difference between flat wire motors and round wire motors is that they use a single flat wire instead of multiple strands of round wire. Furthermore, they utilize a unique winding and forming process, significantly improving their slot fill rate.
How much of an improvement? The pure copper slot fill rate (excluding the copper wire insulation thickness) of flat wire motors is 20% higher than that of round wire motors! While traditional round wire distributed motors have a maximum pure copper fill rate of 48%, flat wire hairpin motors can achieve 70%!
