SMC Materials: Breaking Through the Mass Production Barrier for Axial Flux Motors | JIUJU Motor Automatic Assembly Lines

The push in today's NEV industry is clear: higher power density, tighter integration, lower cost. Traditional electromagnetic materials and manufacturing processes are hitting their performance ceiling. How to squeeze more power out of less space while keeping production costs down has become the central challenge for automakers and component suppliers alike. Höganäs, the global leader in powder metallurgy, is tackling this head-on — leveraging advanced materials and forming processes to deliver solutions that balance performance and cost.

3D Magnetic Circuit, Enhanced Motor Performance

Precision Molding, Optimized Drive Components: Traditional motors rely on a laminated silicon steel process and employ a two-dimensional magnetic circuit design, resulting in poor spatial adaptability and inherent limitations in electromagnetic design. Hegnas Somaloy® soft magnetic composite material (SMC), made from high-purity iron powder coated with a nano-insulating layer, possesses isotropic electromagnetic properties that support the free three-dimensional flow of magnetic flux, unlocking entirely new approaches to motor magnetic circuit design. Combined with a high-pressure near-net-shape forming process, the material can be directly processed into complex, irregular shapes, effectively reducing the volume of end windings to accommodate compact motor designs while suppressing eddy current losses under high-frequency operating conditions. This material serves as the core component of axial flux motors, helping to reduce motor weight and increase power density. It is also widely used in automotive fuel pumps, water pumps, air conditioning compressors, and DC/DC converter reactor cores, balancing equipment operating efficiency with high-frequency magnetic saturation performance.

Precision Molding, Optimized Drive Components

Automotive drivetrain systems impose stringent requirements on component wear resistance and fatigue strength. The traditional steel forging plus machining process generates significant scrap and involves long lead times, resulting in persistently high processing costs for complex, irregularly shaped parts. Hegnas’ near-net-shape powder metallurgy process enables the one-step forming of critical transmission components. The transfer case sprocket can be precision-formed with its tooth profile in a single step, reducing machining operations and material waste; integrally formed planetary carrier assemblies eliminate coaxiality deviations caused by welded subassemblies, enhance torsional fatigue strength, and improve the vehicle’s NVH performance; differential gears combined with surface densification technology can withstand high torque during start-up and acceleration, and their uniform internal microstructure extends component service life under alternating loads.

 High-Strength Materials Ensure Chassis Safety

Vehicle batteries increase the vehicle’s curb weight, placing significantly greater stress on the chassis and braking system. Hegnas’ powder metallurgy technology specifically addresses the challenges posed by heavy chassis loads: shock absorber pistons feature precisely controlled internal porosity for self-lubrication, while integrally molded throttle holes enable precise adjustment of suspension damping; specialized friction powders enhance the thermal conductivity of brake pads, mitigating high-temperature brake fade and ensuring driving safety. Furthermore, powder metallurgy processes can produce lightweight, thin-walled body structural components that balance rigidity, vibration resistance, and cost-reduction requirements. Leveraging its comprehensive powder metallurgy technology, Hegnas provides full coverage across the three core sectors of electric motors, powertrains, and chassis, helping new energy vehicles overcome manufacturing bottlenecks and achieve dual breakthroughs in both high performance and low cost.

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