Machines for electric mobility

WST Koradi is a trusted Italian supplier of spring machinery and an official distributor of Wafios equipment for the e-mobility industry. The company provides state-of-the-art solutions for manufacturing hairpins, enameled copper coils, and busbars, ensuring high precision and efficiency in large-scale production.

FTU series – efficient solutions for enameled copper coil production

The Wafios FTU 1.5 and FTU 2.5 torsion machines are designed for mass production of simple torsion springs, widely used in automotive, electrical, and home appliance applications.

Key benefits
- intuitive programming – the WPS 3.2 EasyCam system simplifies electronic cam programming, reducing setup times and increasing flexibility.
- optimized production costs – higher performance improves unit cost efficiency, particularly for high-volume manufacturing.
- reliable and precise – a robust machine structure ensures repeatability and consistent quality.
- tool compatibility – the machine supports existing FTU-series toolsets for seamless integration.
- copper coil processing – an optional stripping device enables enameled copper coil production.

FMU E series – advanced hairpin bending technology

The FMU E series introduces a patent-pending rotary bending process, ensuring precise, damage-free hairpin production without requiring frequent tool changes.

Flexible programming with WPS 3.2 EasyWay
The Wafios WPS 3.2 EasyWay control system allows for direct geometric programming, eliminating the need for manual CNC axis adjustments. It also supports automated 3D model imports (STEP/IGES files) to accelerate setup.

Innovative machine concept for e-mobility
- bending process simulation – this feature enables feasibility checks and collision prevention, improving production planning.
- patented hairpin tool system – a combination of rotary draw bending and conventional wire bending prevents material slippage, ensuring accurate leg positioning.
- modular process integration – the FMU E series can incorporate stripping, burr-free cutting, and chamfering for a streamlined production workflow.

SpeedFormer – high-speed hairpin production for mass manufacturing

The Wafios SpeedFormer offers a new, cost-effective approach to producing hairpins for electric motors, integrating three well-established wire and tube bending processes into one system.

Smooth transition from prototype to mass production
The SpeedFormer uses the same bending technology as the FMU E, ensuring a seamless scale-up from prototyping to full production.
Cycle times are significantly improved, from 6–10 seconds per hairpin down to just 1–1.5 seconds.
Unmatched production flexibility

- 3D bending without shape-specific tools – this eliminates the need for frequent tool changes, allowing for varied hairpin geometries on a single system.
- integrated quality control – smart camera systems monitor and verify key dimensions like leg positioning and contact surfaces in real time.
- compact and efficient – the SpeedFormer is designed for high-output production while maintaining a space-saving footprint and cost-effective investment.

BMF series – advanced CNC busbar bending technology

The Wafios BMF series is a CNC-controlled bending machine designed for busbars and profiled parts, offering a new approach to precise, high-quality bending in electromobility applications.

Next-generation bending capabilities
Unlike traditional bending systems, the BMF series features a fully automated 3D bending process, where the wire feed rotates instead of the bending head, ensuring greater accuracy and efficiency.

Key features for high-precision busbar production
- ultra-tight radii & twisting – the patent-pending bending tool achieves tight bends with minimal spacing.
- flat wire cutting & stripping – a specialized cutting mechanism ensures clean, burr-free edges, while an integrated laser stripping device allows precise contact placement.
- custom tooling for profiled wire – the machine includes adapted straightening, bending, and cutting tools for processing profiled wire.
- independent programming & simulation – an offline programming system enables feasibility tests before production, optimizing manufacturing efficiency.