Abstract: A method of making a stator includes providing a yoke, wherein the yoke comprises a spray-formed yoke; providing a tooth ring, wherein the tooth ring comprises a spray-formed tooth ring; separating portions of the tooth ring to form a plurality of teeth; arranging the separated teeth in a circular pattern, wherein each separated tooth is spaced from an adjacent tooth; inserting a coil over each separated tooth, wherein the coil includes two lead wires extending from a same face of each coil; locating the yoke onto the plurality of teeth; placing a housing onto the yoke; and connecting the coils to each other at the two lead wires extending from the same face of each coil.

Abstract: A method for spray-forming a component comprises spraying a soft magnetic composite material through a nozzle and into a mold; and adjusting a position of the mold relative to a position of the nozzle to control a deposition of the soft magnetic composite material into the mold. Adjusting the position of the mold relative to a position of the nozzle is carried out with mounting the mold on a stage such that the mold is movable relative to the nozzle and the spraying of the soft magnetic composite material is controlled to provide the deposition of the soft magnetic composite material to form the component in a near-net shape.

Abstract: A system for producing a soft magnetic material having a core-shell structure includes a gas supply configured to supply at least one gas; and a furnace configured to receive the at least one gas. A flow of the at least one gas is configured to be varied to provide a shell on a particle in the furnace.