Advanced Motor Materials
Soft Magnetic Composites
3D-magnetic powder metal components for electric motors
Symmco has in-house capabilities to fully process SMC materials from compaction to electromagnetic testing. With production equipment designed specifically for SMC materials, we can provide any type that you choose for your application.
What are soft magnetic composites?
The metal powders that form the basis of SMCs consist of high-purity iron particles individually coated with an electrically insulating coating. The powder metallurgy process combines with the powder’s specific properties to create parts with three-dimensional magnetic properties.
More and more motor designers are considering the performance, form factor and cost benefits of SMCs for magnetic motor components. However, the range of available materials and design options may appear discouraging.
You can count on Symmco’s experience in powder metal manufacturing in general and with SMCs for motor components in particular to help lead the way. Symmco’s engineers can discuss your manufacturing process, part options, material selections and other questions you may have about designing with SMCs.
Performance That Redefines Motor Design
SMC-based frameless motors deliver more torque per kilogram, at higher efficiency, in a fraction of the weight.
Efficient
- Unprecedented efficiency at low RPM
High Torque
- 60 Nm/kg peak
- 27.5 Nm/kg continuous
- 170mm OD frameless motor
Light Weight
- 1/5th the weight of competing electric motors
*Compared with similar frameless motors from leading manufacturers.
Applications
Well-suited applications are those where higher torque is required. In most cases, motors are used where gearing was previously required. If size, weight and efficiency are critical, the importance of the SMC motor technology is greater yet.
Electrical actuators
High torque to replace gear reduction or hydraulics.
E-bikes, scooters & smaller vehicles
Benefits from lightweight, high torque, and high efficiency.
Larger fans
High torque allows for directly driving loads that previously required gears.
Drones & small manned aircraft
High torque and light weight allow larger, more efficient thrust generation, while running slow enough for quieter propellers.
Direct drives for machines
Higher torque can shrink current motor designs and increase the capabilities of equipment.
Wheel motors
Replacing gears or reducing weight while improving efficiency strongly improves wheel-motor applications.
Automation
High torque drives loads that previously required gears, with higher precision.
Robotic vehicles
High torque allows for directly driving loads that previously required gears.
Equipment & Processing Capabilities
Production equipment built specifically for soft magnetic composites, from compaction through electromagnetic testing.
Compaction temperature controllers
Electronic die temperature controllers using specified water flow rates to maintain a target temperature +/-1° up to 195°F.
Heat treatment
Furnace equipment specifically designed for processing all SMC materials including Somaloy 1P, 3P, and 5P.
Toroidal winding equipment
Automated toroid winding equipment for quick and consistent coils to ensure accurate magnetic testing.
Magnetic testing
Computer controlled equipment for fully automated recording and analysis of DC and AC hysteresis loops up to 20kHz.
SMCs may be the best solution for your electric motor
Soft Magnetic Composite (SMC) material utilizes pressed and thermally-treated powder metal to produce components with 3D magnetic properties. These encapsulated iron powder particles are compacted to form uniform isotropic components with complex shapes in a single step.
The use of these materials makes innovative electrical machine designs technologically viable.
Material Benefits
- Lower electrical losses result in greater efficiency at lower RPM.
- Compact direct-drive motors able to replace hydraulics or gear boxes in a smaller space with less cost and longer life.
- Scalable designs for applications such as e-mobility, wheel motors, actuators, industrial fans, and pumps.
- Robust component construction using fewer parts to reduce cost and improve reliability with no maintenance.
- Less noise, less heat, higher power, increased productivity, more capabilities, and higher efficiency.
Designing a motor with SMCs?
Contact one of our Applications Engineers for help with your design needs, or download the full Somaloy product portfolio.