OEMs and Tier 1 suppliers in the field of electric drivetrains are facing
growing demands to improve the performance, efficiency and scalability of their drive systems at
. One important factor that is now reaching industrial mass production is
composite-based rotor sleeves. These lightweight, high-performance components offer significant advantages in terms of
the mechanical support of rotor components to achieve more efficient designs for high-speed rotations – especially in demanding automotive, aerospace and industrial applications.
After nine months of joint research, a consortium of 15 leading companies – Arkema
Group, Covenstro Deutschland AG, DOMO Engineering Plastics Europe S.p.A., Hexcel Composites SASU,
Huntsman Advanced Materials, Hutchinson SA CRI, Kümpers GmbH, LG Electronics Deutschland GmbH, Maru
Hachi Corporation, Rassini Supensiones S.A. de C.V., Schunk Kohlenstofftechnik GmbH, Swancore
Netherlands B.V., Syensqo, Toray Carbon Fibres Europe S.A., Toyota Motor Europe N.V./S.A. – completed a comprehensive analysis and benchmarking project under the
management of AZL Aachen GmbH. The
project systematically analyzed the state of the art and compared materials, design strategies and
processing methods for rotor sleeves made of carbon fibre-reinforced thermosetting and
thermoplastic materials. The result is a comprehensive market and technology analysis that is documented in
a 384-page final report – and ready for implementation in collaborations.
To support OEMs and motor developers in utilizing these findings, AZL
is now hosting a web meeting specifically designed to demonstrate the practical relevance, supply chain maturity
and technical details of composite rotor sleeves for electric drives. Participation is
free of charge.
The event provides a strategic overview of the possibilities of the technology and demonstrates the
concrete potential for integration into series production. It begins with an introduction to the
current state of the technology and its role in the development of the next generation of
electric motors. AZL then presents the consolidated results from the work packages of the
project. Key findings include comparisons of rotor sleeve designs
(press fit vs. direct winding), material classes (carbon fiber reinforced thermoplastic and
thermoset plastics), mechanical and thermal performance benchmarks, and production KPIs.
In the second part of the meeting, participants will have the opportunity to get to know the consortium behind the recently
completed project – from composite material suppliers and machine manufacturers
to rotor sleeve producers. Each partner will briefly present their unique expertise and offerings to help OEMs find reliable contacts for implementation projects.
Fabian Köster, Development Engineer Composites at Schunk Kohlenstofftechnik GmbH, explains: “As a technology leader and high-volume manufacturer in the field of rotor reinforcements, Schunk
considers it crucial to play an active role in shaping innovations. Participation in the AZL project underlines our conviction that
can ensure future viability and competitive strength through early involvement in technological developments at
. The AZL information event offers OEMs and partners along the entire
value chain a valuable opportunity to exchange information on the current status of motor armoring and
trends, provide impetus and develop joint solutions for the challenges of tomorrow
.”
For OEMs, this event offers an overview of new technologies as well as direct access
to a ready-to-use partner network. It also marks the official start of a follow-up project.
This follow-up initiative will shift from theoretical analysis to experimental validation. Its
aim is to benchmark the performance of different material and process combinations under real production and
operating conditions.
The following project comprises four work packages. The first work package defines the production concepts and
materials to be tested experimentally, including the design of test methods and
auxiliary equipment for press-fitting processes. The second work package aims at a production process consisting
of separate winding and press-fitting on the rotor. It includes the production of sleeves using
wet winding, tow-prep winding and thermoplastic tape winding. The strength testing of the cores
takes into account different pre-stressing levels, while at the same time the quality of the laminate
is evaluated. The third work package comprises the same investigations, but in this case for a
process in which winding is carried out directly on the rotor. The evaluation also includes high temperature tests and
long-term durability. Finally, in the fourth work package, all process and strength test results
are evaluated in terms of cost, quality and performance, leading to a benchmarking of different materials
and clear recommendations for cost-efficient rotor cores.
The web meeting, which will take place on September 25, 2025, is open to OEMs, motor developers,
innovation managers and system integrators who want to accelerate their next generation electric powertrains
. A registration link will be provided to all interested participants.
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