Vehicle Traction Electric Machines Enabled by Novel Composite Magnetic Powder Material and Electrophoretic Deposition Insulation Material

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OPEN 2021
Columbus, Ohio
Project Term:
05/16/2022 - 05/15/2025

Technology Description:

The Ohio State University team will transform the design and manufacturing processes of electric machines for electrified vehicles (EVs) through innovative magnetic and insulation materials. First, the team will develop a novel composite magnetic powder material with high electrical resistivity, a strong magnetic field, and low resistance to magnetization changes and use it to build the electric machine cores, enabling a new class of power-dense and high-performance electric machines. Second, the machine stator material will be coated with ceramic electrophoretic deposition insulation, with 10X higher thermal conductivity than state of the art. With these new materials and manufacturing methods, the team aims to significantly improve torque density by 40% to 70%, and reduce the manufacturing costs of electric machines for EVs.

Potential Impact:

If successful, this project’s outcomes can revolutionize the design concept and manufacturing of the electric machine industry.


Approximately 2.8 million light-duty EVs were sold in 2020 globally, which is approximately a $3.4B market. A 15% to 20% annual increase is expected in the next decade. The proposed new magnetic and electrical insulation materials will positively transform the design and manufacturing processes for millions of EVs produced every year.


This innovative approach will not generate any scrap metal in the stator core manufacturing process.


The proposed technology will reduce manufacturing costs and scrap metal waste, and consume significantly less energy in manufacturing compared to conventional silicon steel laminations that go through energy intensive manufacturing process including hot rolling, cold rolling, intermediate annealing.


ARPA-E Program Director:
Dr. Philseok Kim
Project Contact:
Dr. Julia Zhang
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Project Contact Email:

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