In-house brushless motor manufacturing for complete supply chain control.
The sUAS motor market is dominated by Chinese manufacturers. Building motors domestically eliminates our most critical supply chain vulnerability.
T-Motor, the industry's most popular motor manufacturer, was added to the Commerce Department Entity List in 2024. Many "affordable" motor suppliers operate from Shenzhen with opaque supply chains. For defense applications, this is unacceptable.
Our F Series motor program brings brushless motor manufacturing to Huntsville, Alabama - creating American jobs while ensuring supply chain integrity.
From raw materials to flight-ready propulsion
Silicon steel laminations are stacked and bonded to form the stator core. Precision stamping creates the tooth geometry that determines motor efficiency.
Copper magnet wire is wound around stator teeth in specific patterns. The winding configuration (turns, gauge, termination) determines KV rating and performance characteristics.
Neodymium magnets are bonded to the bell housing in alternating polarity. Magnet grade (N52, N48, etc.) and geometry determine torque and thermal performance.
CNC machined aluminum bell housing, base plate, and shaft. These components require tight tolerances for proper bearing fit and concentricity.
Stator is pressed into base, bearings installed, and rotor/bell assembly mated. Each motor undergoes spin testing and performance verification.
100% inspection and testing. Each motor is serialized and traceable to component lots for full supply chain visibility.
Sourcing strategy for each motor element
| Component | Material | Supplier Strategy | Origin |
|---|---|---|---|
| Magnets | N52H Neodymium | Bunting, K&J Magnetics | USA |
| Stator Laminations | Silicon Steel | Domestic stamping houses | USA |
| Magnet Wire | Copper, polyimide insulation | Superior Essex, MWS Wire | USA |
| Bell Housing | 6061-T6 Aluminum | CNC machining (in-house/contract) | USA |
| Base Plate | 6061-T6 Aluminum | CNC machining (in-house/contract) | USA |
| Shaft | Hardened Steel | Precision ground shafts | USA |
| Bearings | Steel, ceramic hybrid | NSK, NTN | Japan (Allied) |
China controls 80%+ of global neodymium supply and processing.
This is the most significant supply chain vulnerability in domestic motor manufacturing. While magnet suppliers like Bunting and K&J Magnetics operate in the USA, the raw rare earth materials often trace back to Chinese sources.
This challenge affects all domestic drone and EV manufacturers. We're actively working with suppliers to build resilient supply chains.
Scaling from prototypes to volume production
Use KDE Direct Blue UAS motors for initial production. Develop and validate F Series prototypes in parallel.
Establish motor winding and assembly line in Huntsville facility. Begin F Series production for internal use.
High-volume motor production supporting 200+ drones/day. Potential to supply other domestic manufacturers.
Authorized partners can access detailed F Series motor drawings and specifications in our Members area.
Members AccessWe're seeking partnerships with magnet suppliers, CNC shops, and wire manufacturers to build the domestic sUAS motor supply chain.