A method of producing a stator assembly for a fan assembly comprising: - providing a cylindrical inner housing having an outer surface and a cylindrical outer housing having an inner surface and an outer surface; - providing a plurality of stator blades; - defining a mounting orientation and position for each of the stator blades with respect to the outer surface of the inner housing and the inner surface of the outer housing; - mounting each of the stator blades to the inner housing; characterized in comprising: - providing an airfoil-shaped aluminum extrusion having at least one internal cavity; - cutting the aluminum extrusion into the plurality of stator blades; - machine cutting a first end of each of the stator blades such that the stator blade first ends have a compound cut that is curved in one direction and linear or straight in another direction and can be flush mounted to the inner housing in the mounting orientation and position; - machine cutting a second end of each of the stator blades such that the stator blade second ends have a compound cut that is curved in one direction and linear or straight in another direction and can be flush mounted to the outer housing in the mounting orientation and position; - flush mounting the stator blades to the inner housing and outer housing and securing the blades to the inner and outer housings (54, 20) with mechanical fasteners that engage with anchor cavities in the stator blades, such that the stator assembly is capable of supporting and housing an electric drive motor, guiding the airflow from a fan wheel smoothly around the motor, and straightening the airflow leaving the fan wheel. - providing a cylindrical inner housing having an outer surface and a cylindrical outer housing having an inner surface and an outer surface; - providing a plurality of stator blades; - defining a mounting orientation and position for each of the stator blades with respect to the outer surface of the inner housing and the inner surface of the outer housing; - mounting each of the stator blades to the inner housing; - providing an airfoil-shaped aluminum extrusion having at least one internal cavity; - cutting the aluminum extrusion into the plurality of stator blades; - machine cutting a first end of each of the stator blades such that the stator blade first ends have a compound cut that is curved in one direction and linear or straight in another direction and can be flush mounted to the inner housing in the mounting orientation and position; - machine cutting a second end of each of the stator blades such that the stator blade second ends have a compound cut that is curved in one direction and linear or straight in another direction and can be flush mounted to the outer housing in the mounting orientation and position; - flush mounting the stator blades to the inner housing and outer housing and securing the blades to the inner and outer housings (54, 20) with mechanical fasteners that engage with anchor cavities in the stator blades, such that the stator assembly is capable of supporting and housing an electric drive motor, guiding the airflow from a fan wheel smoothly around the motor, and straightening the airflow leaving the fan wheel.