Silicon Steel Foil
Silicon 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 is a leading UK manufacturer of precision Silicon Steel Foil, engineered for high-frequency, low-loss electrical and magnetic applications.
Our ultra-thin foils, typically between 20-200 μm, deliver exceptional magnetic efficiency, low hysteresis, and reduced eddy current losses – making them ideal for EV motors, high-frequency transformers, and advanced power electronics.
Every roll of foil is manufactured for dimensional stability, coating integrity, and long-term reliability, supporting industries at the forefront of electrification and efficiency.
What Is Silicon Steel Foil?
Silicon Steel Foil is a thin sheet of electrical steel (2-6.5% silicon) with enhanced magnetic properties, rolled to micrometer precision.
Key Advantages
- Ultra-thin (20-200 μm) for minimal core loss.
- High magnetic permeability for smooth flux flow.
- Ideal for high-speed, high-frequency electrical systems.
- Compatible with amorphous and nanocrystalline hybrids.
Its ultra-thin design dramatically reduces eddy current losses, improving performance in compact, high-frequency devices. Unlike traditional laminations, silicon steel foil enables engineers to design smaller, quieter, and more efficient machines.
Benefits of Using Silicon Steel Foil
| Category | Benefit | Description |
|---|---|---|
| Electrical & Magnetic | Lower Eddy Currents | Thinness restricts circulating currents, improving efficiency at high frequencies. |
| High Magnetic Permeability | Easy magnetisation/demagnetisation for low energy loss | |
| Reduced Hysteresis Loss | Silicon content improves magnetisation efficiency | |
| Design & Engineering | Compact, Lightweight | Enables smaller, lighter designs without performance compromise |
| Improved Thermal Control | Lower losses = less heat, longer component life | |
| Reduced Noise | Low magnetostriction structure for quieter devices | |
| Sustainability | Energy Savings | Increased efficiency reduces electricity consumption. |
| Eco-Optimised Design | Enables greener, more compact power systems |
Silicon Steel Foil delivers efficiency, miniaturisation, and sustainability – essential for EVs, renewables, and power electronics.
Applications of Silicon Steel Foil
| Sector | Use | Benefit |
|---|---|---|
| Power & Energy | Transformers, inductors, reactors | Reduced core losses and improved power density |
| Automotive & EVs | Traction motors, onboard chargers | Compact, lightweight motor designs with higher range |
| Aerospace & Defence | Actuators, control motors | High power-to-weight ratio for flight systems |
| Electronics & Communications | EMI shielding, sensors | Reduced interference and precision magnetic control |
| Industrial & Robotics | High-speed motors, converters | Improved performance at high rotational speeds |
| Medical & Research | MRI systems, instruments | Quiet, energy-efficient operation in precision systems |
Manufacturing & Material Ecosystem
Stephens Gaskets produces silicon steel foil using a full suite of coatings, adhesives, and assembly technologies to ensure reliable integration in electrical systems.
| Material Type | Function | Example |
|---|---|---|
| Silicon Steel Foil | Magnetic core | 2-6.5% Si, precision-rolled |
| Insulation Coatings | Prevent shorting | Organic (epoxy), inorganic (phosphate) |
| Bonding Adhesives | Foil assembly | Heat-cured epoxies, polyimides |
| Conductors | Magnetic windings | Copper, aluminium |
| Thermal Management | Heat dissipation | Silicone pads, epoxy resins |
| Protective Materials | Environmental protection | Encapsulation compounds, varnishes |
| Advanced Alloys | Hybrid systems | Amorphous or nanocrystalline foils |
Pain Points (and How We Solve Them)
| Challenge | Solution |
|---|---|
| Fragile, ultra-thin material handling | Precision slitting, lamination, and automated stacking prevent damage. |
| High manufacturing cost | In-house processing and volume optimisation keep costs competitive. |
| Bonding & coating reliability | Proprietary insulation and heat-resistant adhesives ensure durability. |
| Thermal stress in high-frequency use | Advanced coatings improve thermal dissipation. |
| Limited global supply | UK-based production for secure, fast delivery. |
| Custom thicknesses & grades | Tailored foil thickness (20-200 μm) and coatings per application. |
FAQs – Silicon Steel Foil
What is silicon steel foil used for?
It’s used in transformers, EV motors, inductors, and shielding systems to reduce energy losses and improve high-frequency performance.
How thin is silicon steel foil?
Typically between 20 and 200 micrometres, depending on the grade and application.
What makes it better than standard laminations?
It drastically reduces eddy current and hysteresis losses, boosting efficiency in smaller, lighter systems.
Can you supply custom coatings or bonded stacks?
Yes – we offer bespoke coatings, adhesives, and foil stacks matched to your engineering needs.
Is it compatible with amorphous or nanocrystalline materials?
Yes. We produce hybrid magnetic cores combining silicon steel foil with advanced alloys for extreme performance.
Stephens Gaskets is the UK’s trusted Silicon Steel Foil manufacturer, delivering innovation in energy-efficient magnetic materials.
Call: 0121 544 5808 | Email: sales@stephensgaskets.co.uk
Request yourSilicon Steel Foil quotation today.