Thermal-stable rotor with enhanced cooling design for efficient electric motor applications

L and shorten the thermal path. The rotor/shaft were shortened accordingly to raise stiffness and the critical speed, lowering vibration. Aluminum die-cast endcaps and a finned AL6063-T5 aluminum housing (a high-conductivity alloy commonly used for motor cooling applications) raised the effective heat-transfer area and conductivity relative to cast iron. Rewinding with a larger wire gauge (0.70 mm × 2) halved phase resistance (18.63 Ω → 8.57 Ω), cutting copper loss. Under full load, input power decreased from 3,420 W to 2,632 W, a reduction of approximately 788 W (23%), and the hottest coil fell by up to 24 °C W (∼16.2%), with rear-section vibration reduced by up to 5.5 mm/s. Complete CAD files, bill of materials, and step‑by‑step build/validation instructions were released under the open-source CERN-OHL-S v2 license (a share-alike hardware license that permits reproduction, modification, and redistribution), enabling replication and adaptation. This work offers a practical template for cost‑effective, thermally robust small induction motors.