Engineers’ Hub for Electric Motor Efficiency

Electric motor design is about more than just reducing cost -- it’s about the chance to get innovative and exceed performance expectations.

If you’re already experimenting with new electric motor solutions that are a little "different,” consider incorporating powder metallurgy (PM) into your plan. Whether you’re looking for electric motor efficiency or cost reduction, chances are a PM solution exists.

Use this hub as a resource for understanding the advantages of powder metallurgy for motor applications vs. competing technologies like electrical steel laminations. Below you can learn more about the untapped potential powder metallurgy holds for motor makers -- and how you can use it to push the boundaries of your design.

Electric Motor Efficiency Through Materials & Processes

Using powder metal parts to cut costs is nothing new. Using powder metal components to further the “electrification” of transportation and other electromagnetic applications is the new frontier for driving performance and cost-efficiency to new heights.

In the case of transportation, these opportunities go far beyond the traditional automobile. Powder metallurgy processes and materials are seeing more use in:

E-bikes
E-scooters
E-motorcycles

Powder metal materials and processes can optimize both AC and DC motors -- everything from axial flux motors to magnetic torque tunnels. Basically, anything that needs to be small and efficient needs to include metal powder parts.

Resource: 3 Trends in Manufacturing Auto Parts: Does Powder Metal Have a Place?

Design Flexibility

A powder metal part is born when premixed iron alloy is pressed into a desired shape to produce 3D structures. Because it’s a material-efficient, net-shape process, it’s dramatically easier and more efficient to design with powder metal vs. machining or another subtractive process.

Think about how engineers place electric car motors on the front or rear axle -- space is at a premium. Today it’s possible to redesign the motor with powdered metal components to use space more efficiently. You can use the extra space to include other components or just make the entire product smaller and lighter!

Advanced powder metallurgy manufacturers are here to help e-motor designers meet the increasing demand for smaller electric and hybrid motors.

Resource: Electric Motor Efficiency & 4 Other Uses for Soft Magnetic Composite

Cost Reduction

Cutting costs for a growing variety of pressed and sintered motor components remains the heart of powder metallurgy.

If your current design is cumbersome and producing excessive scrap, consider a redesign with powder metal. PM produces a more compact design with virtually no leftover material -- scrap waste rarely exceeds 3%.

Sometimes powder metallurgy can even reduce the number of parts needed in an assembly traditionally made with electrical lamination steel.

Resource: Soft Magnetic Composites: A Visual Crash Course on Improving Motor Efficiency

MEET YOUR CONSULTANTS

Fran Hanejko is an industry-leading expert who works with Horizon as our Senior Advanced Materials Engineer. Fran has decades of experience in powder metallurgy, including managing customer applications for a world-leading raw material supplier. He graduated from Drexel University in 1974 with a master’s degree in materials engineering.

Contact Fran with your materials questions by filling out the form on this page.

Tom Freemer, our Director of Technology & Business Development, has worked as a design and material development expert for a world-leading raw material supplier. Today, Tom collaborates with design engineers across several industries to create innovative PM solutions, whether it’s through an advanced manufacturing technique or a unique material alloy. He graduated from Penn State University in 2000 with a degree in materials engineering.

If you have questions relating to the PM manufacturing process, fill out the form and get in touch with Tom.

Decoding Hysteresis Loss in DC Motors With the BH Magnetization Curve

Looking for the right material and process for your metal project? You can learn a great deal about the properties of a material by studying its magnetic hysteresis loop. You can also learn how to minimize losses in DC machines (and maybe even ACs too!).

Is Powder Metallurgy a Green Technology? Here Are 3 Facts to Prove It

Powder metallurgy is a manufacturing process that’s a leading candidate for both prototype and end-use parts across an increasing range of industries. More design engineers are turning this technology because of its ability to provide a low-cost or better-performing part. But there's another reason the powder metallurgy process has become popular -- out of necessity.

What is Sintered Metal?

When you start investigating how powdered metal parts are made, learning about sintered metal is essential. Many of the things we love most about powder metallurgy can be traced back to the sintering process.

Advantages of Powder Metallurgy Vs. Die Casting

When order volume exceeds a few dozen, process economics dictate a near-net shape manufacturing process with little after-work necessary. Many engineers and buyers gravitate to die casting, but there are good reasons for considering powder metal -- especially as new uses, materials, and design possibilities are unlocked thanks to evolving technology and understanding of powder metallurgy (PM).

The Future of Internal Combustion Engine Design: 5 Trends for 2020

The invention of the internal combustion (IC) engine was a boon to transportation and efficiency and all things America. But, as IC technology ages and environmental concerns increase, alternatives are looking to take its place.

What Is Soft Magnetic Composite?

In recent decades, trends in automotive and other industries have spiked demand for new magnetic materials. As a result, in the mid-1990s the very first components made from soft magnetic composite were born. And the trend of using these soft magnetic composites (SMCs) only continues to grow.

Engineers’ Hub for Electric Motor Efficiency

Electric Motor Efficiency Through Materials & Processes

Design Flexibility

Lighter Weight

Rapid-Response Applications

Magnetic Performance