Because of high efficiency, compact structure, axial flux motors(AFM) become more and more popular recent years.

Stator is an essential part for AFM, complex structures are full of challenges for traditional laminations.

As we know, In the production and cutting process, materials can't be used well, resulting in a lot of waste. The traditional method of making the generator stator is to punch out the silicon steel sheet through an ordinary punch, and then manually superimpose the silicon steel sheet and the insulating paper pad one by one, and then make it by manual pressing, welding and other processes, paint and dry. Disadvantages are:

1. The assembly of silicon steel sheets and insulating paper pads is superimposed one by one, the processing technology is cumbersome and complicated, and the work efficiency is low;

2. Through manual processing, the labor intensity is high, and the labor cost is high, thereby improving the processing Cost;

3. Manual lamination, the quality is difficult to guarantee, and the insulation effect is poor.

While the concentricity and result is not ideal. For mass production, stamping/punching mould has been used to punch the stator shape. The mould cost is around $5000, but it can just produce about 2000pcs products. Perhaps a new punch mould head should be replaced which will cost about $1500.

   Let’s move to soft magnetic composites (SMCs), SMCs can use powder metallurgy (PM) way to produce, the material utilization rate is higher than 97%, on the other hand, it can reduce the price of the product and is environmental friendly. The products shape can be realized one step by press, any additional reprocessing is unnecessary.

   Each of the purity iron particle is covered with organic and inorganic material which can make the function of insulation. So we needn’t to make extra insulation, and the insulation is much better than laminations. The special insulation layer makes SMCs have 3D flux characteristics and isotropic, they help designers free their thought, to make electric machines be smaller and lighter. This is the obvious advantages comparing with traditional laminations.

   For one pair of SMC moulds, they can produce at least 10,000pcs products or even more. After the whole comparison, we can conclude that SMC is much more suitable for AFM.