Figure 1. COSTR Closed-Loop Motor Production Workflow

The Hardware Integration Advantage

One of COSTR's most distinctive capabilities is the seamless integration of precision metal hardware manufacturing directly into our motor production process. While most motor manufacturers rely on external suppliers for enclosures, shafts, flanges, or custom housings, COSTR designs and produces these critical components in-house.

Our facilities include high-precision CNC machining centers, advanced mold development workshops, automated stamping and cutting lines, and dedicated assembly teams for mechanical components. This integration enables us to achieve exceptional dimensional consistency, optimize electromechanical matching, and significantly reduce lead times across the entire product lifecycle. We bring together expert teams with extensive international plant management experience and ISO 9001:2015 certification. Our production lines integrate research, precision machining, and automated flow control to ensure complete traceability and consistent delivery quality.

Five Core Motor Manufacturing Processes

COSTR's competitive advantage lies in the depth and precision of each step in our motor manufacturing chain. These are highly engineered modules contributing to a complete production system.

Stator Core Manufacturing

We utilize high-durability tungsten carbide molds and premium-grade silicon steel sheets with lamination thickness of 0.35mm. This ensures extended tool life, minimal iron losses below 2.5W/kg, and superior magnetic efficiency in every motor core.

Advanced Coating System

Our automated electrostatic epoxy coating line employs Class H insulation materials meeting IEC 60085 standards. These coatings provide exceptional heat resistance up to 180°C, superior corrosion resistance, and uniform surface coverage even in complex geometries.

Precision Winding Assembly

We use thermally-resistant enameled copper wire with performance ratings up to 220°C (Class H). Our automated winding systems apply precise layered arrangements to ensure optimal slot filling rates of 70-75%, excellent three-phase balance within ±2%, and minimal copper losses.

High-Performance Rotor Assembly

Every rotor undergoes single-setup CNC machining for maximum concentricity and precision. Rotors feature high-energy sintered neodymium magnets (N42-N52 grade) inserted via fully automated positioning systems and balanced to ISO 1940 G2.5 standards. SKF precision bearings guarantee low noise operation and extended service life exceeding 10,000 hours.

Motor Final Assembly & Testing

Each motor unit undergoes complete electromagnetic simulation and comprehensive validation testing. We support custom signal interfaces, compact form factors, high torque density configurations up to 3.5 Nm/kg, and optimized power density designs reaching 2.8 kW/kg. From ultra-compact flat motors to high-torque joint actuators, our solutions integrate seamlessly into demanding applications.

Quality Standards & Capacity

As embodied in our factory motto, "Precision Machining, Quality First", COSTR views quality as a fundamental value embedded in every process step. Each component undergoes detailed in-line inspection using Zeiss coordinate measuring machines and comprehensive functional validation including back-EMF testing, torque ripple analysis, and thermal cycling. Our production capacity reaches up to 8 million precision coils and 200,000 assembled motors monthly, with custom solution lead times as short as 4-6 weeks for standard configurations.

Why Global Clients Choose COSTR

COSTR is among the few motor manufacturers in China that offers both closed-loop motor production and independent precision hardware capabilities under one roof. This means we are not dependent on third-party vendors for critical metal components, enclosures, or precision machining. Every tolerance, every joint, and every mechanical fit is designed, tested, and optimized within our controlled system.

Your product, whether it's a compact servo motor, a torque-dense actuator, or a fully custom electromechanical assembly, is engineered as one cohesive, fully traceable system.

Key Client Benefits:

• Accelerated Development Cycles with 24-hour prototype turnaround and dedicated project engineers

• Enhanced System Stability through tighter electromechanical integration and optimized component

• matching

• Predictable Lead Times enabled by our internalized supply chain and production control

• Responsive Engineering Support with real-time design feedback during optimization phases

• Single-Source Accountability one point of responsibility for both motion performance and mechanical

• precision

Our Capabilities:

• Complete production ecosystem from raw materials to finished systems

• Integrated mechanical and electrical manufacturing under one roof

• Professional international engineering team with global OEM experience

• ISO 9001:2015, RoHS compliance, and CE marking certifications

• Trusted by tier-1 clients across automation, robotics, and precision equipment sectors

From advanced robotics to industrial automation systems, our clients choose COSTR because we engineer motors as integrated systems, not isolated components.