I am designing a motor in numerous sizes and would like, if possible to cast the stator. The ideal solution would be an iron power filled resin that could be poured into a silicon mold, use RIM or compression molding. Compressing iron power directly may be another option since the stator is not a structural component. Basically I am looking to improve the manufacturing process from using a punch to cut thin silicon steel components. Thoughts?

The motor design is available for review:

http://humanoidplatform.wordpress.com/2012/05/25/motor-gearing-and-controller-designs/