The axial flux motor offers numerous advantages over other motor types, including an increased power density, a more compact magnetic path, greater torque, and improved cooling, as any motor enthusiast would know.

Given all of its benefits, why don't more manufacturers incorporate axial flux motors into their designs?

The fundamentals of axial flux motor operation will be covered here, along with how soft magnetic composites (SMCs) can assist in resolving the main challenges in the manufacturing of axial flux motors.

What Makes an Axial Flux Motor Unique?
Because of the way it is wound, an axial flux motor generates flux across to the axis of spinning. This has the benefit of making the motor winding process simpler and lowering the total cost of assembly.
Because axial flux motors employ copper winding more efficiently, they can increase the amount of turns and decrease the heat generated by the end turn effect.
Prior to the development of brushless DC motors and the availability of powerful permanent magnets, which could take advantage of the benefits of axial geometry, the use of axial flux motors was uncommon.

Why Pick Motors with Axial Flux?
Axial flux motors have a special set of advantages over other kinds of motors, such as:

1）They have a torque density that is more than 10% higher, depending on the size of the package; some yokeless axial flux motors claim a 400% torque density.
2）Because the windings of axial flux motors are not incorporated in the steel laminated materials and frequently have more air flow across the coils, they are easier to cool.
3）Axial flux motors avoid excessive heat generation because they lack end turns. To get the wire back into the laminating stack in radial flux motors, end turns are required. The windings of axial flux motors are wound around the motor's pole.

4）It is perfect for applications like power tools, wheel hub motors, drones, etc. because of its improved power to weight ratio.
5）Shape is more economical when using SMCs technology and is perfect for manufacturing.

Challenges in Implementing the Axial Flux Motor (And How PM Can Assist)

Nowadays, the most used technique for producing rotors and stators is still stacking laminations. This is a drawn-out procedure that includes:
➤ Using a stamp or wrapping
➤ Put together
➤ Gluing, welding, or riveting
➤ Cutting the axial poles
The internal structure of the material may be deformed by cold-working in these expensive procedures, which raises the dislocation density and weakens the material's magnetic qualities.

However, there is good news. High-efficiency motors are now possible thanks to powder metallurgy, especially when soft magnetic composites (SMCs) are used. Powder metallurgy can also assist reduce costs. Here's how:

➤ Compact Size

The internal saturation levels are higher with SMCs and powder metallurgy. This saturation value is crucial because it enables manufacturers to use smaller motor components while maintaining the same magnetic efficiency.

➤ Reduced Cost

Taking assembly and material waste into account, cost has been the main barrier to axial flux motor adoption. SMCs minimize or virtually eliminate waste by offering a more compact motor design and net-shape manufacturing of the stator.

➤ Greater Torque

For a given volume motor, axial flux motors usually exhibit torque of 10% or more. More than 400% torque gain is quoted by certain manufacturers.