The move toward electric mobility has intensified demand for traction motor technologies characterized by high efficiency, power density, and thermal stability, among other attributes. Hairpin stator configuration has gained significant industrial attention due to its compact winding architecture, improved slot fill factor, and enhanced electromagnetic performance. However, the environmental impacts of the hairpin stator production remain insufficiently assessed. This study presents a life cycle assessment (LCA) of hairpin stator production from cradle to gate, highlighting key environmental hotspots. In contrast to previous prototype-oriented studies, the present work conducts a comprehensive LCA of hairpin stator production for high-performance applications under real industrial conditions beyond the prototypical stage. The analysis follows a standardized LCA methodology per ISO 14040 and ISO 14044, covering the life cycle stages from raw material extraction and materials processing to stator hairpin manufacturing. The life cycle inventory data are compiled from industry sources, literature, and the Ecoinvent database. The results are modelled using SimaPro software, and the Environmental Footprint (EF 3.1) method is used for life cycle impact assessment (LCIA). The impacts are analysed and presented at the midpoint level across the following impact categories: global warming potential (climate change), resource depletion potential, acidification potential, ecotoxicity, eutrophication potential, ozone depletion potential, and photochemical ozone formation. The findings enhance a broader understanding of sustainable manufacturing strategies for electric traction motor designers, original equipment manufacturers, electric vehicle manufacturers, and policymakers.
Keywords
- Cradle To Gate
- Electric Mobility
- Hairpin Stator
- Life Cycle Assessment (Lca)
- Sustainable Manufacturing