We are pleased to welcome Cast Coil GmbH as an exhibitor at Drone Days 2026—a young company with technology that has the potential to fundamentally transform electric propulsion systems.
Cast Coil was spun off from Fraunhofer IFAM in July 2023 and has brought a patented process for manufacturing cast coils for electric machines to market. Instead of conventional wire windings, the coils are made from copper or aluminum using a casting process. The result: a slot fill factor of up to 90 percent, compared to the previous maximum of 55 percent for wound coils. In tested electric drives, copper cast coils achieved up to 100 percent higher continuous torque, while aluminum cast coils are 40 percent lighter than conventional copper windings—with 30 percent fewer CO₂ emissions during production.
This technology is highly relevant to the UAS industry: In the growing market for electric aviation, there is a demand for electric propulsion systems that deliver maximum power while keeping weight as low as possible—exactly what cast coils make possible. From multicopter propulsion systems to VTOL air taxis, cast coils can significantly increase the power density and energy efficiency of electric propulsion systems.
Would you like to participate as an exhibitor? You can find all the information you need about registration here.