A rotary actuator includes an outer enclosure having an inner diameter surrounding a hollow interior. A stack of stator laminations, each having a stator diameter greater than the inner diameter of the outer enclosure when in an unflexed state, are also included in the rotary actuator. Each of the stator laminations is configured to flex into a shape so as to be positionable within the outer enclosure and substantially conform to the inner diameter. The stator lamination thus forms a line-to-line fit with at least a portion of the outer enclosure to form an interface having a desirable reluctance.