Even as HVAC systems adopt smart sensors, variable-speed drives, and connected controls, one component hasn’t kept pace: the traditional laminated-steel motor core.
Standard HVAC motors operate at 85–92% efficiency, which looks respectable but hides a massive opportunity. Across the global HVAC installed base, even a 2–5% efficiency gain can translate into billions of kilowatt-hours saved.
Electric motors drive 35% of total electricity consumption in homes and commercial buildings, with HVAC and refrigeration consuming the majority. Yet the magnetic architecture inside most motors has barely changed in a century. While the industry has transformed the digital layer, the magnetic heart of the motor remains stuck in 2D.
Traditional HVAC motors rely on laminated electrical steel stacks. This design is proven, but it’s inherently restrictive:
As HVAC systems shift toward variable-speed operation, laminated cores reveal their weaknesses:
In short, the limitation isn’t the material — it’s the geometry.
Motor inefficiency compounds across the entire HVAC system. Consider AI data centers, where cooling consumes up to 40% of total energy use. These systems often rely on tens of thousands of small, high-speed motors, almost all of which are built on laminated cores. Even a 3% efficiency increase can provide material energy savings at scale, reduced thermal cycling, and improved uptime. The same is true for residential and commercial HVAC units: small efficiency gains in motors = large lifetime savings.
Soft magnetic composites (SMCs) enable a shift from 2D to true 3D magnetic architectures. SMCs are powdered iron particles insulated and compacted into near-net-shape 3D forms. This gives engineers design freedom that’s impossible with laminations:
The Value Add
Horizon specializes in manufacturable, cost-effective SMC motor components, helping HVAC manufacturers and design teams convert theoretical performance into scalable products.
We provide design teams with the next-gen support they need for innovative motor design:
In real HVAC motors, SMC-based architectures typically achieve 2–5% higher efficiency versus conventional small-frame laminated designs.
The next leap in HVAC performance won’t come from smarter algorithms; it will come from rethinking the motor itself. Horizon combines advanced simulation with manufacturable 3D magnetic components to help HVAC innovators reach their goals:
This is not about reinventing the motor. It’s about smarter engineering.
As electrification accelerates, sustainability targets tighten, and variable-speed systems become the standard, motor architecture will be a deciding factor in the next generation of HVAC systems. Horizon Technology partners with manufacturers, design engineers, and system integrators to bridge the gap between material capability and system performance, helping turn bold ideas into manufacturable reality.
Let’s reimagine what HVAC efficiency can look like—and build it together.