>> Each layer of that strip has a different cut in it, so its much more complicated to make.

You can roll a spool of that material and then machine the shape out of it. I've seen this done for axial flux motors. There are other approaches as well, and the cost differences get even smaller if you throw automation at the production process. I used to believe axial flux motors were one of those oddities that won't win in the end, but now that I work with them I'm not so sure. They are at least competitive with radial flux machines.

Can you (or anyone) explain where the power density improvement comes from with axial flux? When I work through the first-order math it seems like it should come out the same as radial flux. Is it just that the geometry allows better cooling from the coils? Or the use of grain oriented steel?

I was wondering where the seam is supposed to be in that picture and then it turns there is no seam. It's just one continuous roll.

https://www.youtube.com/watch?v=6ZVQWgk6tRc