This research presents a numerical model for simulating the winding process of the rotor for Renault’s Electrically Excited Synchronous Motor. The rotor winding process is complex. Operating with minimal curvature radii during deposition subjects the copper wire to high bending and tensile deformations, causing defects such as wire misalignment and gaps between layers, which can compromise the motor’s electrical performance and increase the risk of short circuits. The objective of this research is to simulate the winding process by modeling frictional contact interactions between the wire and moving rigid obstacles, and by driving the moving tools on realistic trajectories in order to reproduce and understand the origin of observed defects. This allows for an accurate determination of the final coil geometry, which is largely dependent on the residual stresses resulting from successive plastic deformations. The study extends the internal software Multifil capabilities, which relies on an implicit solver for the behaviour of entangled media and metallic cables [1]. The model employs a Finite Element Analysis approach for the wire, treating it as a one-dimensional beam model with a deformable cross-section with elastoplastic behaviour. The frictional contact interactions between the wire and the rigid obstacles (modelled using simple analytical surfaces to reduce computational simulation cost) and the self-contact between different wire segments are managed using a penalisation method and a regularised Coulomb's law. Validation was performed through bending tests (”Wire-to-Nozzle distance test”) and simplified simulations of multi-turn deposition. The results demonstrate the model’s capacity to capture experimentally observed phenomena. Quantifying defect severity is crucial for Renault, as reducing it would allow optimisation of the copper/iron ratio, thus improving motor efficiency. In conclusion, this model provides a robust foundation for the detailed analysis and parametric optimisation of the winding process, reducing experimental testing and enhancing the performance of Renault’s electric motors.