Method of making a servo motor with high energy product magnets

A method of making an electric motor with the stator winding inside a slotless cylindrical stator shell comprising the steps of:

• forming a slotless cylindrical stator shell of magnetic material;
• creating a generally cylindrical support with a reduced diameter portion at one end;
• forming the winding around said support from preformed coils such that
• the coil and turns at one end of said support flare inwardly and extend adjacent said reduced diameter portion, and
• the coil end turns at the other end of said support flare outwardly;
• inserting said winding into said cylindrical stator shell starting with the inwardly flared end coils while the winding is supported by said support;
• impregnating said winding with a resin to secure said winding inside said stator shell;
• and
• removing said support from the winding through said end having said outwardly flared end coils.