Integrated magnetics, insulation, and cooling architecture for robust eVTOL motors

To address the NASA need for advanced technologies that will improve the safety and reliability of the electrical power system/powertrain of UAM vehicles, specifically advancements in thermal management technologies for electric motor systems, Hinetics proposes to develop a new Integrated Magnetics, Insulation and Cooling Architecture (MAGICA) that can help break the trade-off between power density and reliability, and obtain robust, high power motors that can be produced in high volume. This approach reduces electro-thermal stresses at the windings, which are traditionally viewed as the most vulnerable sub-system in motors for electric aircraft. The significantly improved dielectric protection extends the SOA on several fronts including thermal degradation, insulation quality, and partial discharge, preventing winding failure while retaining high power density and system-level benefits. The system offers enhanced electro-thermal performance with the unique infusion of cooling and magnetics, alleviating the iron yoke as a thermal bottleneck, reducing T between the heatsink and coils, and creating sufficient thermal headroom to enhance the coil insulation without degrading motor performance. Combined with modular manufacturing and pre-qualification of the coil assembly offering independent quality assurance, this provides a path to meet NASA requirements for high reliability and safety in cost-effective, mass production. In Phase I, Hinetics demonstrated the feasibility of MAGICA through a combination of computer modeling, design/analysis, and the fabrication and test of a laboratory prototype, reducing development risks for Phase II. MAGICA has now reached TRL 4; in Phase II, Hinetics will expand the capabilities of MAGICA with integration into two fully functional generators, achieving TRL 6 at the projects conclusion. The demonstrated results will offer NASA and eVTOL OEMs the ability to extend motor/generator performance while prioritizing utmost reliability. MAGICA is a three-pronged approach which improves the thermal and dielectric performance of a high performance slotless PMSM developed at Hinetics, making it more torque dense and robust. The topology consists of three independent thermal improvements: A ceramic coil holder holds the form-wound Litz conductors and introduces a side-wall parallel heat path from windings to heat sink. The ceramic also improves dielectric integrity, reducing the risk of insulation failure and partial discharge activity. Periodically interleaved copper laminations in the yoke stack acts as a thermal shunt for the flux-supporting magnetic iron and its relatively poor thermal properties. An additively manufactured heat sink improves air-side heat transfer through increased surface area of an axially varying geometry. The combined topology resulted in a 35% reduction in temperature rise from coolant to winding hotspot in the prototype, providing several options for customers: ~24% increase in specific power for same ΔT Lower cooling demand for the same ΔT Lower ΔT for the same architecture and cooling The technical objectives of MAGICA Phase II are as follows: Uncover the extended realizable design space of slotless PMSM electric machines through multi-objective EM-thermal optimization of the MAGICA-infused topology. Demonstrate the applicability of MAGICA to several applications while working through full-scale assembly practicalities with the design, fabrication, and full-load testing of two 100 kW-scale electric machines targeting differing vehicle platforms. Prove demonstratable reliability with benchtop experiments on sub-components; includes structural, dielectric, and thermal verification of the ceramic coil holder. Mature TRL and move towards commercialization; develop detailed plans for mass production and certification. In accordance with the project’s technical objectives, a program involving the design, build, and demonstration of two separate generators is envisioned. Each generator will target a specific application of parties who have expressed significant interest in employing Hinetics machines into their systems. Taking this approach allows us to simultaneously mature the MAGICA technology through full machine integration and move towards commercialization by developing products specifically designed to meet the requirements of two potential customers.

When complete, MAGICA will help improve the safety and reliability of the electrical motors used in UAM powertrains. Hinetics has developed a series of machines ranging from the 20-500 kW class, relevant to the NASA Revolutionary Vertical Lift Technology (RVLT) project’s concept vehicles, to MW-class high speed machines for the Electrified Aircraft Propulsion program within ARMD. These motors can be readily retrofitted with MAGICA to increase reliability as we scale to volume production. MAGICA enables reliable, safe operation of high power UAM aircraft. This will have uses for Government applications such as civil and military disaster relief, search and rescue, medical evacuation, firefighting, and commercial applications such as urban air mobility and cargo transport. With little alteration, MAGICA will also be capable of motors for commercial hybrid-electric regional aircraft.

This is early/mid-stage (TRL 5) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

None of these are guaranteed paths for this specific project — TechPort itself doesn't have an "apply" button. Reaching out to the contact(s) above with a specific question is usually the fastest way to find out what's actually open.