Electrical Steel Foil
Electrical Steel Foil
Call 0121 544 5808 Today
Bespoke Manufacturing
Instant Quote Service
Worldwide Delivery
Various Gauges/Thicknesses
Bespoke Manufacturing
Instant Quote Service
Worldwide Delivery
Various Gauges/Thicknesses
Stephens Gaskets manufactures precision electrical steel foil for the next generation of high-frequency and high-efficiency electrical systems.
Our ultra-thin magnetic foils – ranging from 20 to 100 μm – deliver exceptional energy efficiency, reduced core losses, and superior performance in compact devices such as EV chargers, transformers, and aerospace power systems.
Our ultra-thin magnetic foils – ranging from 20 to 100 μm – deliver exceptional energy efficiency, reduced core losses, and superior performance in compact devices such as EV chargers, transformers, and aerospace power systems.
Each foil is engineered to meet your exact application, offering cutting-edge materials, tight tolerances, and high-frequency reliability.
What Is Electrical Steel Foil?
Electrical steel foil is an advanced, ultra-thin form of electrical (silicon) steel – typically below 0.1 mm thick.
It’s designed to reduce eddy current losses, improve magnetic efficiency, and perform flawlessly in high-frequency and compact systems.
Why Foil Over Traditional Laminations?
- 80 – 90% lower eddy current losses at high switching speeds.
- Enables miniaturisation for compact systems.
- Lightweight and flexible for advanced core designs.
- Improved thermal control in high-density power electronics
Benefits of Electrical Steel Foil
| Benefit | Description |
|---|---|
| Energy Efficiency | Reduces eddy current losses, improving overall efficiency. |
| Compact Design | Enables smaller, lighter magnetic components – vital for EVs and aerospace. |
| Thermal Stability | Dissipates heat effectively, extending component lifespan. |
| High-Frequency Compatibility | Perfect for inverters, converters, and power electronics. |
| Design Flexibility | Can be wound, layered, or stacked into innovative core geometries. |
| Sustainability | Supports lighter, more efficient electrification technologies. |
In short: Electrical steel foil is the future of compact, efficient magnetic design for modern electrified industries.
Applications
Electrical steel foil is used where conventional laminations are too thick or lossy for performance demands:
1. Power Electronics
High-frequency transformers, DC-DC converters, inverters.
2. Automotive & EV
Onboard chargers, traction motors, and compact inductors.
3. Renewable Energy
Wind and solar inverters, grid integration systems.
4. Aerospace & Defence
Lightweight power systems, avionics transformers.
5. Medical & Precision Electronics
MRI and implant charging systems.
6. Telecommunications
5G power supplies, data centre transformers.
Each industry relies on edge bonded shims for quick adjustability, corrosion resistance, and vibration control.
Industry-Specific Materials
Stephens Gaskets supplies multiple grades of electrical steel foil depending on your application and frequency range:
| Material | Typical Use | Key Advantage |
|---|---|---|
| Silicon Steel Foil (NOES/GOES) | General transformers, motors | Excellent magnetic performance and availability |
| High-Silicon Electrical Steel (6.5% Si) | EV inverters, aerospace power | Ultra-low losses at high frequencies |
| Amorphous Metal Foil | Transformers, renewables | Metallic glass structure = 70% lower core losses |
| Nanocrystalline Foil | Aerospace, medical, high-frequency | High permeability, low loss, compact form factor. |
| Hybrid Insulated Foils | EV and telecoms | Heat-resistant and corrosion-protected coatings. |
Pain Points (and How We Solve Them)
| Industry Challenge | Stephens Gaskets Solution |
|---|---|
| High Cost of Exotic Alloys | Lean manufacturing and in-house tooling reduce costs. |
| Brittle High-Silicon Steels | Precision handling and custom annealing minimise breakage. |
| Complex Foil Winding | CNC-controlled winding and lamination lines ensure consistency. |
| Thermal Stability at High Load | Special coatings improve heat resistance. |
| Limited Global Supply | UK-based production ensures fast, reliable delivery. |
FAQs – Electrical Steel Foil
What is electrical steel foil used for?
It’s used in transformers, inductors, EV chargers, and aerospace systems where high-frequency efficiency is critical.
What thicknesses are available?
Typically 20 – 100 μm, depending on the alloy and application.
What are the material options?
Silicon steel, high-silicon, amorphous, and nanocrystalline foils, each offering specific magnetic and thermal advantages.
Can Stephens Gaskets produce custom foil widths or coatings?
Yes. We offer tailored widths, thicknesses, and insulation coatings for your process requirements.
Is electrical steel foil more expensive than standard laminations?
Upfront costs can be higher, but long-term savings come from efficiency gains, weight reduction, and reduced cooling demand.
Stephens Gaskets is your trusted UK partner for Electrical Steel Foil manufacturing.
From EV components to aerospace power systems, we deliver precision, performance, and dependability in every reel.
Call: 0121 544 5808 | Email: sales@stephensgaskets.co.uk
Request a bespoke quotation for Electrical Steel Foil today.