Precision-Engineered Stator for Automotive Electrification

Industry: Automotive | Application: Electric Stator Component | Material: High-Performance Polymer

Overview

• Leading automotive supplier required a high-precision stator for next-gen electric powertrains
• Needed to meet strict performance, durability, and manufacturing standards

Business Challenges

• Thermal resistance – Withstand high temperatures without deformation
• Electrical insulation – Superior dielectric strength to prevent failures
• Dimensional accuracy – Tight tolerances for seamless integration
• Chemical Resistant - Motor needed to use specific coolant

Objectives

• Develop a lightweight, durable stator
• Ensure high thermal stability & electrical insulation
• Achieve tight dimensional tolerances
• Optimize for high-volume, defect-free production

Solutions Implemented

Material Selection:

• Chose PPS (Polyphenylene Sulphide) + 40% glass reinforcement
• Benefits: 220°C thermal stability, superior insulation, minimal shrinkage

Precision Injection Moulding:

• Used multi-cavity moulding for high accuracy & minimal post-processing
• Optimized cooling to reduce internal stresses

Tooling Innovation:

• Designed custom multi-cavity tool with complex ejector systems
• Achieved ±0.4mm tolerances and optimized polymer flow to prevent defects 

Conclusion

• Stator exceeded thermal, electrical, and precision requirements
• Supported automotive electrification with advanced polymer technology