Do you know PCB stators in axial-flux designs may redefine torque density and cooling?

After working with PMSM and BLDC motors, I see this clearly—

PCB stators in axial-flux designs may redefine torque density and cooling.

Electric motors account for over 50% of global electricity consumption.

That’s right — from cars 🚗 to HVAC systems 🌬️, they’re everywhere.

So every gram, watt, and degree of efficiency matters.

🧠 Let’s understand a breakthrough that’s reshaping motor design —

The Axial-Flux Motor with a PCB Stator.

🔍 What’s inside a motor?

Every motor has two key parts:

Rotor: the part that spins.

Stator: the fixed part that produces the magnetic field.

Traditional stators are made of iron, which is heavy and limits efficiency.

In fact, iron makes up about two-thirds of motor weight!

Now imagine replacing that iron with a Printed Circuit Board (PCB).

A PCB is a thin, layered board with copper traces — commonly used in electronics.

Here, it replaces the iron stator with a lightweight, efficient, and compact alternative.

🌀 Axial-Flux Motor — A smarter design

In an axial-flux motor, the rotor and stator are flat and parallel —

like two disks facing each other.

This design allows higher torque density (more torque per volume)

and better cooling due to its thin profile.

Add a PCB stator, and you get:

✅ 50–65% lighter weight

✅ 25% lower carbon emissions

✅ Half the size and noise of conventional motors

💡 Why it matters

The air-core design (no iron core) reduces energy losses.

In a normal motor, iron causes eddy current losses — unwanted heating and vibration.

The PCB motor avoids this, giving smoother torque and less noise (about 5 dB lower).

It also allows two rotors on each side of the stator, creating a strong and consistent magnetic flux — the invisible field that actually spins the motor.

🧩 Smarter electronics inside

Each PCB layer carries one electrical phase. (A phase is a timed sinusoidal current wave used to create rotation.)

This prevents short circuits and improves reliability.

A Variable Frequency Drive (VFD) — made with high-efficiency silicon carbide MOSFETs — controls motor speed and torque precisely.

It even allows cloud monitoring and software updates 🌐.

🌍 Real-world applications

Infinitum Electric’s PCB axial-flux motors are now used in:

HVAC and ventilation systems 🏢

Manufacturing and industrial drives 🏭

Electric vehicles and hybrid systems 🚘

Even electric aviation ✈️

Oil-cooled versions reach 8–12 kW/kg power density,

making them ideal for EVs and aircraft.

If every motor worldwide adopted this design,

we could cut 860 million tonnes of CO₂ annually —

equal to removing 200 million cars from our roads. 🌱

💭 Do you think PCB-based axial-flux motors will dominate the next generation of EVs and HVAC systems, or will traditional designs still hold ground?

♻️ Share this with your friends & Follow Murali for insights on EVs, Motors & Tech.

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