Unlock the highest torque-to-weight ratio in electric propulsion with our Axial Flux Halbach Arrays.
Suitable for next-generation ‘Pancake’ motors, in-wheel drives, and compact robotic actuators.
These assemblies project a concentrated magnetic field parallel to the rotation axis.
They come with a Halbach arrangement in a flat, circular array.
We amplify the magnetic flux entering the air gap while shielding the back face.
This allows you to design coreless (iron-less) stators.
Or ultra-lightweight rotors without heavy steel yokes.
The result is a motor profile that is thinner, lighter.
And more responsive than traditional radial flux equivalents.
We specialize in the precision assembly of these complex, multi-pole magnetic discs.
Ensure perfect planarity for ultra-tight air gaps.
Engineering & Manufacturing Capabilities
Trapezoidal & Skewed Segment Assembly:
Axial arrays often require complex trapezoidal (wedge-shaped) magnets to maximize packing factor.
We can manufacture and assemble skewed poles.
They mean magnets with angled edges.
Drastically reduce cogging torque and harmonic distortion in high-precision servos.
Planarity Control:
In axial motors, the air gap is often <1.0mm.
A wavy rotor means catastrophic failure.
We use double-disk grinding and optical flatness verification.
Ensure the magnet face is perfectly flat (typically <0.05mm total runout) relative to the mounting hub.
High-Strength Retention:
Axial forces are enormous.
We use aerospace-grade structural epoxies (shear strength >30MPa).
And combine them with mechanical retaining rings (ID/OD).
Or dovetail features to lock magnets in place against both magnetic repulsion and centrifugal loads.
Customization Options
Organize by the specific topology of the motor.
A. Array Topology (Single vs. Double Rotor)
Single-Sided Arrays:
Optimized for single-rotor/single-stator topologies.
Their back-iron mass must be minimized.
Double-Sided (YASA Style):
Matching pairs of Halbach rotors to sandwich a coreless stator.
We supply matched pairs with aligned poles for maximum flux linkage.
B. Magnet Geometry
Standard Trapezoids:
Maximizes active magnet area for highest torque density.
Rectangular Blocks:
A cost-effective alternative for larger diameters.
Their trapezoidal machining costs are prohibitive.
Laminated Segments:
For high-frequency axial motors, we can segment the magnets.
Reduce eddy current heating within the rotor itself.
C. Encapsulation & Protection
Carbon Fiber Face Sheets:
We can bond a thin (0.3mm – 0.5mm) carbon fiber sheet over the active magnet face.
This protects the brittle magnets from physical impact during stator installation and acts as a safety shield.
Titanium Banding:
For high-RPM axial rotors, we install Titanium bands on the outer circumference to prevent radial expansion.
D. Thermal Performance
Axial motors are compact and heat dissipation is a challenge.
High-Grade NdFeB:
We recommend N42UH or N38EH (180°C – 200°C) as a standard.
Prevent demagnetization during peak torque bursts.
Designing for a thin profile?
Minimize your air gap safely.
The biggest challenge in Axial Flux design is maintaining a tight, consistent air gap without magnet collision.
Send us your 3D Step File.
We will review your rotor geometry for manufacturability.
Simulate the Axial Holding Force.
And recommend the best adhesive and retention strategy for your thermal class.
