Use of Insulated Iron Powders in a Bicycle Permanent Magnet Electric Motor

Insulated iron powders are gaining acceptance as alternative materials to steel sheet laminations used in electrical motors. This is being driven by the potential for reduced costs, reduced parts per component, and increased design flexibility due to the isotropic nature of the iron composite materials. Here a systematic approach was used to design an original permanent magnet electric motor integrating an iron composite stator. In the paper are described the different steps involved in the development of this stator. From the first design iterations, to the prototype testing, trials on an industrial press and production. The focus is put on the design, materials and compaction aspects.