PCB Stator Technology

The first DC electric motor capable of moving machinery is invented by British scientist William Sturgeon. His design is later adapted by Thomas Davenport, leading to the first DC motor patent.

Following a period of rapid improvements to motor technology, the first practical DC motor is invented by Frank Julian Sprague. His design is capable of maintaining a relatively constant speed, while completely eliminating sparking.

A significant increase in electric motor efficiencies and reliability is achieved by adding an air gap between the motor stator and rotor.

The invention of the first brushless DC motors increases electric motor reliability and performance by replacing the physical “brush” commutators with electronic commutators made possible by the development of solid state electronics.

The widespread integration of permanent magnets into brushless DC motors is made possible by the greater availability of rare earth metals, increasing their power output significantly.

Jerry Genco and Norman Smith patent a motor with a stator on printed circuit assembly, reducing manufacturing and material costs for permanent magnet BLDC motors. Their design both electrically and mechanically connects the stator to a printed circuit board via the circuit components and contact terminals.

ECM’s advanced modeling software PrintStator is launched and utilized to prototype a mid-drive solution for an electric bike. From discrete inputs, PrintStator automatically generates associated Gerber and drawing files for the 6” stator, sent to a local PCB house for printing.

ECM files three patents: (1) addressing thermal management in PCB stators; (2) addressing winding losses via unique methods, geometries and structures in PCB stators; (3) specific to apparatus and method for forming a magnet assembly.

PrintStator successfully produces “stacked stator” designs, allowing higher operating voltages. ECM acquires 625 patent rights, is granted 3 patents and files 2 additional patents.

PrintStator successfully incorporates CAM sub-routines to seamlessly translate optimized motor design geometry to G-code utilized by CNC machine tools that manufacture component parts, improving overall quality and nearly eliminating operator error.

ECM is granted an additional 3 patents related to PrintStator, granting ECM a total of 10 patents. PrintStator has been used to successfully integrate motors in the e-mobility, HVACR, robotics, maritime and medical industries.

ECM continues to commercialize PCB stator technology, using the PrintStator software to develop optimized PCB stator solutions for many diverse applications. A Design Your Own page is added to the ECM website allowing innovators from many industries to use PrintStator and develop their own custom PCB stator motor. ECM continues to diversify its application portfolio, prototyping PCB stator solutions for consumer appliances, fitness equipment, aerospace, HVACR, precision motion, renewable energy, e-mobility and robotics applications.

Now totaling almost 100 unique prototypes already developed, ECM continues making strategic partnerships with manufacturers, product developers, and innovators in many industries. Stacked motors and segmented stators are some of the features added to PCB stator’s design flexibility. PrintStator designs now range from silver dollar-sized motors up to 24 inches in diameter. ECM’s software development team prepares to launch its PrintStator software package to its customers.

PrintStator BETA trials is launched, four ECM motors are in the process of being outfitted for large scale commercialization, close to 15M motors/yr are slotted for production via ECM’s PrintStator platform.