Overview

Miles Platts, a leader in precision technical moulding, partnered with an automotive manufacturer to develop a bespoke stator tooth solution for a limited-run, high-performance electric vehicle (EV). Our expertise in high-performance engineering polymers and precision moulding enabled us to deliver an innovative solution tailored to the customer’s exacting specifications.

Challenge

The customer required a specialised end insulator and slot wedge for stator teeth to enhance the efficiency and durability of their high-performance electric motor. The components needed to:

• Withstand high temperatures and electrical stresses.
• Be manufactured with tight tolerances for perfect alignment in the stator assembly.
• Offer superior mechanical and electrical insulation properties to improve motor performance and longevity.
• Be designed for efficient production without compromising on quality.

Our Approach

Leveraging our deep expertise in thermoplastics for electrical insulation, Miles Platts:

• Worked closely with the customer to understand design constraints and material requirements.
• Selected a high-performance engineering polymer with exceptional dielectric strength, thermal stability, and mechanical resilience.
• Designed and developed precision injection-moulded components with tight tolerances to ensure a seamless fit.
• Conducted rigorous quality control and testing, ensuring each part met the required electrical and mechanical performance standards.

Results

• Optimised Motor Performance: The precision-moulded stator teeth insulation improved motor efficiency and reduced energy losses.
• Cost-Effective Solution: The injection moulding process ensured consistent quality at scale, making production more cost-effective.
• Enhanced Durability: The selected material withstood high thermal and electrical stresses, extending the motor’s lifespan.
• Successful Integration: The components were seamlessly integrated into the final motor assembly, meeting all functional and regulatory requirements.

Conclusion

Miles Platts' ability to design, tool, and manufacture high-precision stator insulation components played a crucial role in the success of this high-performance automotive project. Our expertise in polymer selection and precision moulding allows us to support the evolving needs of the EV and automotive industry, delivering innovative and reliable solutions for demanding applications.

Looking for a custom-moulded solution for your electric motor project? Get in touch with our team today!