Insulation Technology
What is unique ?
At Drive13, we recognize that high-performance 3D printed windings for electric motors demand advanced insulation solutions. Our proprietary insulation technology is designed to deliver superior electrical, thermal, and mechanical properties, crucial for applications with high power density.
Our insulation has the following features:
❏ Applied to the final shape without bending
❏ No mechanical tension or micro-cracks
❏ Higher breakdown voltages
❏ PD-free insulation
Key Advantages
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Our process allows for film thickness ranging from 25 to 300 µm, offering the flexibility to optimize insulation performance based on the specific requirements of each application.
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We provide access to a diverse selection of insulation materials, extending thermal capabilities up to 260°C, surpassing typical catalogue options. This ensures reliability in high-temperature environments under continuous operation.
○ High-end polymers (180-200°C).
○ High thermal class (220-260°C).
○ Non Organic Coating for extremes (300°C - 400°C). -
By applying insulation directly onto the final bare coil, we eliminate the need for post-processing or mechanical tooling. This minimizes the risk of mechanical stress on the winding, particularly at the end windings, improving long-term durability.
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Our insulation technology ensures uniform protection across all coil surfaces, including sharp corners. This eliminates weak spots where electrical stress can concentrate, preventing premature insulation breakdown. By achieving complete and consistent coverage, we not only enhance dielectric strength but also push the partial discharge inception voltage (PDIV) to its practical limits, resulting in PD-free operation.
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Our insulation process is highly automated, ensuring consistency, scalability, and efficiency. This results in a more streamlined production workflow, reducing manufacturing time and improving overall quality.
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Our insulation method offers enhanced flexibility and uniformity, allowing us to cover complex coil geometries.
With these advancements, our insulation technology not only enhances the electrical performance of 3D printed windings but also contributes to higher reliability, efficiency, and cost-effectiveness. This makes it an essential component in pushing the boundaries of electric motor innovation.
oUTSTANDING rESULTS
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By achieving precise insulation thickness and tight tolerances, we ensure there is no air between winding turns. This air-free configuration significantly enhances the electrical and thermal performance of the windings, eliminating the risk of PD.
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The absence of air gaps enhances heat dissipation, ensuring that the windings operate at optimal temperatures even under high loads. This contributes to greater overall motor efficiency and reliability.
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The insulation we use significantly enhances the partial discharge inception voltage, increasing the overall electrical stability of the motor and extending its operational lifespan. This capability is critical for high-power-density applications, where long-term reliability and maximum performance depend on eliminating partial discharge risk.
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Our insulation process increases the fill factor by maximizing the amount of conductive material within the available space. This leads to better power density and improved motor efficiency.
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With zero clearance between winding turns, our solution enables higher power output and improved energy efficiency. This results in a more compact and efficient motor design, ideal for high-performance applications. By eliminating the impregnation process and optimizing the winding structure, our insulation technology offers a streamlined, high-performance solution for modern electric motors. This breakthrough not only reduces production complexity but also contributes to superior motor performance and longevity.
Get in touch
Our team will be happy to support your ongoing developments.