Electric motors for aviation and motorsport

Electric motors with the highest power density

Electric motors for extremes! In motorsport and aviation, drives have to overcome extreme challenges. Innovative designs and high-performance materials push the engine to its physical limits and enable power densities of 25 kW/kg and more.

Single coils

Single coils form compact windings for maximum torque densities. The 3D printing of the coil takes it to a new level: maximum copper fill factors, optimised winding heads and functional integration. The perfect geometric adaptation not only enables higher efficiencies than with the classic round wire winding, but also better heat dissipation, a more compact design and wiring.

3D-printed electric motor, specialised design for electric aviation
innovative concept for electric motors in high-frequency applications

Opti Slot

Different conductor structures in one stator – the perfect adaptation of the stator winding drastically reduces current heat losses. This applies in particular to fundamental winding frequencies above 500 Hz, which otherwise cause high AC losses. The OptiSlot concept combines round wire, litz wire, nextpins and hairpins in the same slot. This guarantees the most efficient solution for every application!

Electric drives in Aerospace

Electric motors can be used for pumps or coolant compressors in aerospace applications. State-of-the-art liquid cooling systems and additively manufactured components enable power densities of over 100 kW/liter.

Modern insulation systems and adapted conductor wiring reduce partial discharges in electric motors, even in a vacuum.

Electric motors can be used for pumps or coolant compressors in aerospace applications. State-of-the-art liquid cooling systems and additively manufactured components enable power densities of over 100 kW/liter.
integrated oil cooling in electric motors

innovative cooling concepts

There are many ways to cool electric motors, from air cooling and water cooling to direct oil cooling.
Direct oil cooling in particular enables high performance in the smallest possible installation space and with low weight. The unique combination of forced heat transfer between conductor and laminated core allows power densities of over 25kW/kg.

Phase Change Cooling

The world’s most efficient cooling system: Phase Change Cooling takes electric motors to their physical limits. The cooling system utilises the high enthalpy of vaporisation of the special cooling medium to achieve a heat dissipation of 60 kW/l. The physical properties of the coolant allow direct cooling of the stator windings, giving the best possible heat transfer coefficient.

If heat is introduced during the phase transition, the temperature of the cooling medium does not rise any further, so that the motor operates constantly at a maximum of 120°C. The continuous output of the motor corresponds to the maximum output and there is no derating.

electric drone with highly efficient motors

Functional safety

In order to fulfil the high requirements of the applications, we rely on the latest technologies for electrical insulation. We use high-end polymers that are selected specifically for the application. They enable continuous operating temperatures of up to 260°C, unrivalled chemical resistance and the highest partial discharge inception voltages!

State-of-the-art insulation

Functional safety concepts include redundantly connected motor windings. The parallel active paths guarantee that operation is maintained even in the event of a failure (fail operational). Additive Drives supports your concept with innovative busbar designs and state-of-the-art insulation technologies. The result is highly efficient designs in the smallest possible installation space, with high power density.

Development for the planet

Today’s electric motors often utilise technologies from the last century.
With increasing demands for energy efficiency and CO2 savings, the need for new solutions to make the future of drive technology more sustainable is also growing.

Additive Drives was founded out of a deep desire for more innovation and has developed into a pioneer of electric drives. For years, we have been dedicated to developing new technologies in order to realise a new generation of electric motors. With solutions such as the Next-Pin, we have the future of electromobility on offer.

Technology

Customised electric motors: Depending on the application, different conductor structures and technologies can be used: Single coils, classic hairpin windings with optimised winding heads or the patented Additive Drives Next Pin!