Soft Magnetic Composites
Electric motors made with soft magnetic composite (SMCs) stators are currently contributing to a new wave of technological advancement in electrification. Manufacturing stators from SMCs, instead of steel laminates, reduces eddy current losses, increases power and allows for more design flexibility.
Design Freedom
Metal powder can be formed into a myriad of possibilities. Additionally, SMCs allow for three dimensional magnetic flux flow, meaning designs can be compact while remaining high in torque density.
Manufacturing Efficiency
SMCs are pressed metal powder components. Powder metallurgy achieves near-net shape manufacturing with extremely low scrap rates, consistent dimensional accuracy and high-volume production.
Performance Advantage
Each SMC metal powder particle is insulated resulting in lower eddy current losses (compared to steel laminates) and improved efficiency.
Soft Magnetic Composites for the Next Generation of Electric Motors
Soft Magnetic Composites from Porite combine advanced powder metallurgy with engineered magnetic performance to enable compact, efficient, and highly customizable electromagnetic components. Designed for modern electrified systems, SMCs deliver unique 3D magnetic behavior, excellent high‑frequency performance, and cost‑effective near‑net‑shape manufacturing.
Design Freedom
Traditionally, electric motors have been manufactured with laminated steel stators. The laminated steel has some inherent limitations that soft magnetic composites are able to improve upon. First, pressing powder into the required shape allows for various designs not achievable through the use of laminated steel. Second, the three dimensional magnetic flux enabled by SMCs means that designs that would not make sense with steel laminates are now possible. The result is higher torque density alongside compact designs and increased efficiency.
Manufacturing Efficiency
Like all of Porite’s powder metallurgy products, SMCs are pressed and sintered with precision allowing complex shapes with minimal secondary operations. The powder metallurgy process creates minimal scrap resulting in low production cost. As with all powder metallurgy products the manufacturing process produces stators with consistent dimensional accuracy ideal for high-volume production.
Performance Advantage
Each soft magnetic composite particle is individually electrically insulated. Additionally, the powder metallurgy assembly process is less damaging to the material than the competing steel laminate assembly process. Both of these factors contribute to an electric motor that functions with dramatically lower eddy current losses compared to transitional motors. Lower core losses means improved efficiency, higher torque, cooler operation temperature and the ability to design more compact assemblies.
Applications
High Speed Electric Motors (electric vehicles & more)
Electric Bicycle Motors
Automotive Actuators & Solenoids
EV Pumps, Compressors and Auxiliary Systems
Magnetic Cores for Power Electronics
Contact us today to get started on your soft magnetic composite project.