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<p>In drones, Brushless DC (BLDC) motors, rotors operate at high speeds, requiring adequate strength, dimensional accuracy, and thermal stability. Therefore, metallic rotors are preferred. Conventional manufacturing methods such as machining, and casting involve higher material waste and lower productivity. Sheet metal forming offers a viable alternative for producing components with better material utilization and productivity. This work introduces a redesigned rotor of EMAX RS2205 BLDC motor, specifically for sheet metal forming. Rotor geometry is reengineered from its baseline machined configuration to satisfy formability constraints while also achieving significant weight reduction. In addition, airflow-enhancing features are incorporated into rotor design to improve cooling performance. The manufacturability of redesigned rotor is evaluated using AutoForm simulations. Furthermore, structural response under centrifugal loading and airflow characteristics are also analysed. Results demonstrate that the proposed design enables lightweight construction, improved thermal performance and is feasible for high-volume manufacturing.</p>

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Sheet Metal-Formed Rotor Design for High Volume Electric Mobility Manufacturing

  • 期刊论文

  • 发表日期：

    2026年6月19日

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  • Aditya Avinash Jadhav,
  • Febins Jose,
  • P. P. Date

摘要

In drones, Brushless DC (BLDC) motors, rotors operate at high speeds, requiring adequate strength, dimensional accuracy, and thermal stability. Therefore, metallic rotors are preferred. Conventional manufacturing methods such as machining, and casting involve higher material waste and lower productivity. Sheet metal forming offers a viable alternative for producing components with better material utilization and productivity. This work introduces a redesigned rotor of EMAX RS2205 BLDC motor, specifically for sheet metal forming. Rotor geometry is reengineered from its baseline machined configuration to satisfy formability constraints while also achieving significant weight reduction. In addition, airflow-enhancing features are incorporated into rotor design to improve cooling performance. The manufacturability of redesigned rotor is evaluated using AutoForm simulations. Furthermore, structural response under centrifugal loading and airflow characteristics are also analysed. Results demonstrate that the proposed design enables lightweight construction, improved thermal performance and is feasible for high-volume manufacturing.