Proving the SMC Value Proposition for a High-Volume eMotor

Background

Höganäs, a leading materials supplier, set out to demonstrate the potential of soft magnetic composite (SMC) technology in a high-volume traction motor equivalent to the VW ID.4. To inform customer positioning and investment strategy, they required a fast, system-level evaluation showing whether SMC-based motors could outperform conventional laminated steel (LSS) machines in efficiency, energy consumption, and total cost of ownership (TCO).

Approach

ePOP was used to rapidly model and compare SMC and LSS motor architectures for an ID.4-class traction application. Motor-CAD designs were imported into ePOP and paired with common inverter and drivetrain assumptions to ensure an apples-to-apples comparison.

ePOP then simulated all concepts across WLTP and ADAC cycles, quantifying losses, efficiency, energy use, and TCO. This workflow enabled hundreds of design variants to be evaluated within days and provided clear visibility into the system-level impact of both current and next-generation SMC materials.

Outcome

The updated modelling showed that under realistic, correlation-driven assumptions, today’s “7P” SMC material does not outperform laminated steel – clarifying discrepancies observed in previous studies. However, incorporating the new “9P” next-generation SMC material reversed the conclusion: across WLTP and ADAC cycles, SMC machines delivered consistently lower energy consumption and lower TCO than equivalent LSS designs.

Comparative scatter plots in the revised dataset – particularly those on pages 6–7 showing the ADAC cycle with updated material properties – demonstrate a clear shift. The strongest SMC concepts (notably SMC6, SMC5 Dist B, and SMC3 Dist) outperform their LSS counterparts (such as LSS3) on both efficiency and TCO.

These findings confirm that with advanced material grades, SMC technology is not only competitive but often preferred for high-volume traction motors in ID.4-class applications. The study validates the architectural direction established in project P21233 and shows that next-generation SMC formulations make the performance and cost advantages decisive.

{{result}}