As part of the EFFICoil (Resource-Efficient, Flexible Manufacturing and Testing Processes for High Performance Coils) project, the feasibility of replacing round copper wire turns with rectangular aluminium coils was investigated. Both the electromagnetic performance and the manufacturing process were simulated. A novel production process was developed for geometry-adapted coil formers, allowing individual winding shapes to be optimised for slot filling, improved machine performance, and cost-effective use of aluminium. Forming tests were performed and validated using selected measurement techniques.