Producing axial flux motors economically: How Lambda Resins enables series production through material and process innovation

Axial flux motors are considered a highly efficient alternative to the classic radial motor: they offer higher torques per unit volume, a lower power-to-weight ratio and reduced consumption of raw materials – especially 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, reducing the air gap by over 60 % results in more power with the same power consumption – or, conversely, in significant savings in energy consumption.

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 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 cast 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.