Boston-based ECM’s proprietary motor design and optimization software, PCB PrintStator, enables engineers to design, model and prototype printed circuit board stator motors.
Unlike traditional radial flux topology that requires large amounts of copper to operate, the ECM printed circuit board stators replace copper windings. An obvious difference in design is that the stator is supported by two parallel rotors that support the magnets. PCB stators are axial flux motors (also known as pancake motors) that have relatively high torque in a compact envelope. Their lightweight form factors, combined with their high torque to weight ratio, make axial flux motors a good choice in many applications, including electric airplanes and EVs.
When ECM President and CEO Brian Casey stepped up to Machine Design’s mic at Automate 2024, he explained why his company’s proprietary motor design and optimization software is making it possible to design a motor for a system, rather than the other way around. Casey likened his company’s optimization software, PrintStator Motor CAD, to SolidWorks or AutoCAD, but noted that it is specifically designed for axial flux motors by leveraging printed circuit board technology.
READ MORE: Axial Flux Motor Topology Signals Next Generation of Electric Motors
“The software is set up for non-deterministic outcomes, meaning it’s a precursor to AI and gives unique solutions for engineers and innovators with their end product,” said Casey. “Engineers can take that solution and have it printed at any printed circuit board house in the world.”
Asked what we could expect to see from ECM in 2025, he said: “We just stay focused on delivering solutions and value to our clients. The pipeline is just immense. We continue to get overtures. So, my guess is I’m going to get pressure to spend a little more money on a larger booth with some better graphics.”
Machine Design: ECM has built a rather unique business offer. Can you explain foundationally how you came up with your concept and how it is evolving?
Brian Casey: Our product offering is unique; it’s not in a traditional motor catalogue setting. And it really [evolved] through the technology, when it first began. To create these unique stator environments, you need powerful software, you need powerful optimization. And once we realized how accurate it was and how useful it was, we had a very simple outlook, which was, instead of just giving people motors, let’s create basically a franchise motor opportunity. So now our clients are becoming their own motor companies. They’re fulfilling their own motor companies because they don’t have to invest in traditional winding lines or big electromechanical processes. Through the power of software, they’re able to leverage printed circuit board printing and bring it all in-house very quickly and simply.
We think it’s a pretty seismic shift in the industry to go from a small, little company to now having clients in pretty much all corners of the globe, big marquee names. And they are now developing their own line of motors. So, I think this is going to have a disruptive impact on the traditional motor offering.
READ MORE: Axial-Flux Motors and Generators Shrink Size, Weight
MD: Can you elaborate on the impact on motor design? How is the software changing the way the industry operates?
BC: That’s a great question about how the software impacts the design capabilities. First off, we’re really giving companies solutions they haven’t had before and some of the attributes of the underlying topology of an axial flux motor are going to be much thinner, much lighter. We have very low noise acoustics, you know, signatures. It’s very quiet with near zero electromagnetic interference and zero cogging.
So, very accurate, very precise, very smooth. The product lends itself to everything from robotics to high tech, but it also has resonated with large HVAC pump companies because we’re able to reduce the form factor and the weight. So, big weight savings, improved performance and improved maintainability. A very durable product.
READ MORE: R&D Spotlight: PCB Stator Technology Replaces Bulky Copper Windings
MD: We’ve talked theoretically until now. Can you provide one or two specific examples that demonstrate how you’re able to change the design and the form factor.
BC: A case in point is a side-by-side look at our traditionally wound stator with the printed circuit board stator. It’s a fraction of the weight.
We’ve had clients come to us because they want a thinner form factor or they want supply chain diversity or they don’t want their competitors to come into their business. We’ve done everything from small haptics. We actually are going to be in a product that’s going to be in gaming simulation, large HVAC and large pumps.
Behind us (see video) is a kitchen appliance, which is a garbage disposal. You never would have thought that would resonate. But we’re able to give different operating modes for a garbage disposal company a little more height under the sink and a fraction of the weight so that it’s easy to install.
When you add up all these attributes, it starts to become compelling, and it allows businesses to offer new innovative products without really changing their whole business to do it.
READ MORE: Protecting Motors Against Overload Conditions Using “I Squared T” Methods
MD: How is ECM staying compliant with regulatory compliance?
BC: On the regulatory front, there continues to be pressure around sustainability and (companies) offering new products that are very sustainable.
There’s a continuing increase in efficiency targets and our technology allows people to hit those efficiency targets in a very quick, innovative, rapid cycle approach. We’re working with people within the Department of Energy (DOE), so they’re aware of the technology and what’s going on.
But you know, everything—as simple as back-fan applications to pool pumps—now requires further regulation on smaller horsepower and smaller size motors. And our software allows these entities and enterprises to create new designs in what I call flash track, in weeks as opposed to taking years. They can meet and exceed efficiency targets in very short order.
