[Analysis of the Development of Coreless DC Motor Industry for {{Humanoid Robot}} Parts] | MIR DATABANK

The year 2025 is seen as the first year of mass production for humanoid robots, with the global industrial process accelerating: Tesla plans to produce 10,000 Optimus units annually, while China's Zhiyuan Robotics has already achieved mass production of thousands of units and is aiming for commercialization in 2025. The collaborative project between Seres and Huawei is also set to enter the mass production phase by the end of the year... In this wave, the dexterous hand, as the core carrier for humanoid robots to interact with the environment, has become the key to technological breakthroughs.

Unlike the specialized grippers of traditional industrial robots, humanoid robots need to cope with complex and ever-changing application scenarios, requiring their actuators to possess both high versatility and flexibility. The realization of this capability largely depends on the precise drive of the dexterous hand—electric drive solutions have become the mainstream choice due to their efficiency and controllability. Among them, coreless motors stand out for their small size and high power density, becoming the "core joints" of the dexterous hand. Taking Tesla's Optimus as an example, each dexterous hand needs to be equipped with 6 motors, with 2 coreless motors for the thumb joint and 1 each for the other 4 fingers. If both hands are equipped with such dexterous hands, a total of 12 coreless motors are required for joint driving.

This article will focus on this high-growth track, providing an in-depth analysis of the key component of humanoid robots—the coreless motor—and exploring its technological barriers and industrial opportunities.

The core hardware of humanoid robots includes linear actuators, rotary actuators, sensors, dexterous hands, etc., among which the dexterous hand is the key actuator for robots to interact with the environment, with a high technical threshold. Unlike the specialized grippers of traditional industrial robots, dexterous hands need to possess high degrees of freedom, high precision, and rapid response capabilities, directly driving the application of coreless motors. According to MIR Industry Research, coreless motors account for approximately 6.7% of the hardware value of humanoid robots.

Coreless motors are not products specifically produced for humanoid robots; their development history predates that of humanoid robots by a significant margin. The basic technology of coreless motors can be traced back to 1958, when German engineer Dr. F. Faulhaber developed the skew-wound coil winding technology, marking the birth of coreless motor technology.

Due to their excellent performance, coreless motor products have a wide range of downstream applications, initially being used in cutting-edge industries such as aerospace and military. In recent years, their application fields have gradually expanded to the civilian market, including medical devices, consumer electronics, power tools, industrial automation, robots, and other scenarios. Currently, the proportion of humanoid robots in the application field of coreless motors remains relatively small. In the future, with the large-scale production of products by Tesla and numerous domestic humanoid robot producers, coreless motors will also usher in broad application prospects and market demand.

Coreless motors are relatively expensive, with the core barrier lying in the self-supporting winding technology. The key points for achieving self-supporting windings are as follows:

1. Winding process design: Different winding methods determine motor performance.

• Linear winding:The process is complex, requiring multiple windings, and is suitable for winding structures with fewer turns and longer lengths.

• Skew-wound coils (e.g., Germany's Faulhaber):Automated one-time forming, with a high qualification rate and good flatness.

• Concentric windings (e.g., Switzerland's Maxon):Higher power density and better performance.

2. Winding equipment: High-end equipment is still dominated by Europe, the United States, and Japan. Although domestic producers have broken through some technologies, there is still a gap in large power and complex structure winding.For example, Zhongte Technology has developed and produced multiple automatic and semi-automatic winding equipment, but the winding principle of its fully automatic dual-axis coreless winding machine still belongs to the roll-type production method. Qinlian Technology is one of the few domestic producers of coreless winding machines that adopts the one-time forming production technology. However, its winding machine can only wind coils with relatively small sizes, thin wire diameters, and simple shapes, which cannot meet the requirements of large power coreless motors.

From a technical perspective, coreless motors can be divided into two categories: brushed and brushless. In their structures, the rotor of a brushed coreless motor has no iron core, while the stator of a brushless coreless motor has no iron core.The brushless coreless motor is suitable for humanoid robots. Its structure is more complex and its cost is higher compared to the brushed coreless motors used in small home appliances and toys, and there is also greater potential for domestic substitution.

Brushless coreless motors do not have carbon brushes or commutators. They mainly achieve electrical energy conversion through electronic converters, automatically adjust the current direction based on the rotor position, achieve spark-free operation, have basically no friction loss, and extend the motor's lifespan. The lifespan of brushless motors is more than three times that of brushed motors. Importantly, they are smaller in size and lighter in weight, aligning with the development trend of robots. Due to their more complex processes and more raw materials, their costs are also significantly higher than those of brushed motors.

Globally, top-tier enterprises such as Switzerland's Maxon, Germany's Faulhaber, and Switzerland's Portescap have long occupied a high market share in coreless motors. Meanwhile, domestic producers are also accelerating their presence in this field, such as Moons' Industries, Dingzhi Technology, Zhaowei Electromechanical, Leadshine Technology, Sanhua Intelligent Controls, Weichuang Electric, Topband, and Hichuan Technology.

Currently, the humanoid robot industry is at a critical stage of product application definition. Numerous producers have launched prototypes and conducted various tests in an attempt to explore the optimal form for scalable and widespread adoption of humanoid robots. In this process, coreless motor companies supplying these humanoid robot manufacturers directly can obtain first-hand application feedback. This enables them to promptly adjust their R&D and product optimization directions. Leveraging the solid foundation built through early joint R&D and technical exchanges with clients, these coreless motor companies are poised to become designated suppliers after the mass production of humanoid robots, thereby gaining a first-mover advantage in the vast future coreless motor market.

Founded in 1994, Moons' Industries is a comprehensive manufacturer in the motion control field, with years of expertise in motor technology, mastering core R&D, drive, and manufacturing capabilities. In 2024, it achieved operating revenue of 2.4 billion yuan, down 4.99% YoY.

According to data from Moons' Industries' official website, the smallest outer diameter achievable by its brushless slotless motors (brushless coreless) is 10mm, with additional models ranging from 13mm to 30mm. The company's coreless motors utilize its proprietary patented coreless winding technology, a special design that delivers high torque, high torsional strength, and low noise, enabling smoother high and low-speed operation, more precise control, and higher efficiency and power density. Annual report data shows thatin 2024, Moons' Industries' brushless motor business generated total operating revenue of 219.51 million yuan, up 31% YoY.

Established in 2008, Dingzhi Technology primarily produces linear actuators, hybrid stepper motors, DC motors, voice coil motors, and their components, serving downstream clients in medical equipment, industrial automation, and other manufacturing sectors. Its full-year 2024 revenue reached 224 million yuan, down 20.80% YoY.

According to its 2024 financial report, Dingzhi Technology has completed the development of coreless motor series ranging from 6mm to 42mm, paired with 6mm-42mm precision planetary gearboxes, designed for various industrial automation needs. These products feature low noise, long life, and high precision, suitable for dexterous hands, door switches, power tools, dental equipment, etc., and are already being supplied to clients, meeting customized requirements.

Founded in 2001, Zhaowei Electromechanical is primarily engaged in the R&D, production, and sales of micro-transmission and drive systems. Its products find applications across multiple sectors, including smart vehicles, consumer and medical technology, advanced industrial and intelligent manufacturing, and robotics. In 2024, the company achieved an operating revenue of 1.525 billion yuan, up 26.42% YoY.

According to the 2024 financial report, Zhaowei Electromechanical has completed the construction of a serialized platform for brushless coreless motors, with all serialized motors achieving mass production. The 4mm brushless coreless motor has overcome technical challenges and entered small-scale production. In the future, the focus will be on developing 4-pole products for brushless coreless motors to enhance product performance.