Axial flux motors - Lambda Resins enables series production through material and process innovation

Axial flux motors are regarded as a highly efficient alternative to the classic radial motor: they offer higher torques per unit volume, a lower power-to-weight ratio and reduced raw material consumption - especially for copper, iron and magnetic materials. However, their industrial implementation has so far remained an exception. The reason: high design complexity, sticky processes and therefore a lack of scalability.

Gluing was yesterday - casting brings the breakthrough

Lambda Resins, a supplier specializing in high-performance resins under the umbrella of the Nagel-Group, has developed a thermally conductive and at the same time mechanically highly resilient casting resin that completely replaces adhesive bonds. Instead of laboriously bonding and thermally treating dozens of individual teeth, the resin system can be used to cast complete stator segments - including coil, tooth structure and insulation - in a single process step. The result: fewer components, shorter cycle times, more robust design, clearly structured process chain - a real technological leap forward.

Technical highlights with immediate efficiency gains

* Thermal conductivity: Enables efficient heat dissipation and protects against overheating - especially in compact designs.
* Structural strength: Mechanically stable under high lateral and tilting forces - a common weak point in bonded modules.
* Adapted expansion coefficients: The resin behaves thermally like the surrounding metal components - no cracking behavior, no delamination.
* Elimination of GRP/CFRP retaining plates: not only reduces material costs, but also allows a significant reduction in the air gap - for more magnetic coupling, higher torque and better efficiency.

Depending on the application, the reduction of the air gap by over 60 % leads to more power with the same power consumption - or conversely to significant savings in energy requirements.

Planning security thanks to reduced infrastructure costs

In conventional production scenarios, an axial flux motor would require over 100 hot pressing stations operated in parallel to achieve a cycle time of less than one minute per stator. With the Lambda Resins potting concept, this effort is drastically reduced: fewer machines, less space required, lower energy consumption - and significantly reduced investment costs.

"We don't just supply a material - we supply a fully integrated production concept that makes the series production of axial motors economically viable," says Uwe Köhler, Managing Director of Lambda Resins.

From resin to line - complete solution from a single source

Together with Gehring Technologies and the Nagel-Group, Lambda Resins has developed a scalable, automatable machine platform that fully integrates the potting process:

* Precise control of filling volume, temperature control and curing
Continuous process monitoring
* Advice on design optimization - from wall thicknesses to thermal paths

This bundled material and machine expertise reduces interface risks, increases process stability and accelerates market access.

Proven in practice - up to 40% increase in performance

In initial projects - for example in the field of electric motorcycle drives - an increase in performance of up to 40% was achieved simply by using the casting resin, without any mechanical changes. The effect: less internal electrical resistance due to better heat dissipation, directly measurable in higher torque and efficiency.

Technological advantage through integration

Lambda Resins offers OEMs and suppliers not just a material, but a scalable complete solution for the next step in drive technology. If you want to make axial flux motors economically viable for series production, there is no way around material and process innovations such as these. Technologically sophisticated, reliably implemented, economically convincing.

Lambda Resins GmbH


Germany

https://www.lambdaresins.de

Herr Uwe Köhler
+49 170 90 94 201

u.koehler@lambdaresins.de

Lambda Resins GmbH is a subsidiary of UNICAST GmbH in Kerpen. UNICAST is a service provider for the development and potting of electrotechnical components. Since 2005, UNICAST GmbH has been serving many branches of industry with expertise in the areas of casting resin, development and processing. This also includes customer-specific developments or modifications of polyurethane and epoxy resin systems. "The high demands of our customers have motivated us to research and develop specifically in the field of highly thermally conductive polymers. Gradually, a narrow path emerged that brought to light completely different results than what was usually expected. The result was an extremely stable casting resin with thermal conductivities of 7-8 W/m*K. We had already cast countless motor stators up to that point, but the performance of this resin was simply unbelievable," says Managing Director Köhler
Thanks to the success and the existing contacts with Nagel, a strategy was developed together at managing director level, which ultimately led to the joint venture between the NAGEL Group and UNICAST. The resulting company, Lambda Resins GmbH, in which both companies are jointly involved, is the manufacturer of Lambdapox. Lambda Resins GmbH develops, produces and distributes this product worldwide. Lambda Resins GmbH will continue to develop many new products in the future. The main aim of these resin solutions is to make modern high-performance electro-technical products and components with improved thermal management even more efficient.

NAGEL Technologies GmbH - technology leader in precision and innovation: Nagel has been a leader in honing and superfinishing for decades and sets global standards in quality and technological development. Through continuous innovation, precise and efficient solutions are developed that give companies a decisive competitive advantage.

With more than 1,800 employees and international locations on four continents, Nagel combines comprehensive expert knowledge with pioneering technology. In addition to the established business fields, new areas in the automotive and non-automotive industry are systematically developed. These include state-of-the-art robot solutions, automation technology and laser coating technologies.

Machines, tools and services from Nagel stand for the highest quality, productivity and process reliability and make a decisive contribution to technological advancement in numerous industries. www.nagel.com

This release was published on openPR.