hofer powertrain

From pre-development to series maturity – engineering expertise across all topologies and use cases:

‍

Development of induction / asynchronous motors (IM / ASM), permanent magnet synchronous motors (PSM), externally exited synchronous motors (EESM), and axial flux motors (AFM) architectures
Development of EM with Pull-in-, concetrated,-, wave-, Hairpin- or Form Litz Wire winding
Requirement engineering, quick concept designs, EM topology and technology benchmarks
Electromagnetic (EMAG) analysis, thermal design including CFD analysis, structural analysis incl. mechanical strength simulations and rotor dynamics, optimizations, design for manufacturing (DFM)
Full in-house prototype build and validation (A / B / C phases)
Industrialization readiness, including supplier coordination and process ramp-up for mass production

Testing, validation, and benchmarking: Confidence through data and measurements

In-house testing from prototype to production for all e-machine types through A/B/C-sample stages
Performance and efficiency measurements

New & innovative winding technologies for higher efficiency

Our Form Litz Wire (FLW) winding consists of several single wires which are twisted and then highly compressed
Form Litz Wire winding with copper fill factors up to 60 to 69%, decreasing not only the DC losses but also significantly reducing AC and PWM losses
Up to 25% more max. continuous power output compared to Hairpin winding
FLW is designed for scalability, using existing Hairpin manufacturing infrastructure
Reduced BOM costs by up to 23% due to shorter active lengths and less material use
Benchmark results verified through OEM and Tier 1 projects across premium segments
To find out more about the benefits and how it is produced contact us: e-maschine@hofer.de

‍

Performance leadership for demanding applications

PSM with FLW winding:

EESM with brushless excitation:

Rare-earth-free, low drag losses, switchable field current for efficiency
Improved thermal stability and cost-saving potential (smaller battery, no disconnect unit)

Axial flux motors (AFM):

‍

Advanced & innovative cooling strategies

We develop bespoke cooling solutions tailored to customer demands, backed by vast expertise in high-performance thermal management:

Direct rotor oil-spray: Efficient cooling for high-speed rotor and magnets.
Stator direct oil cooling: Increased continuous power via direct winding cooling.
Combined cooling: Water-jacket and oil-spray systems for maximum efficiency.
Internal channel cooling: Slot and end-winding cooling for high current densities.
Axial cooling (AFM): Optimized oil cooling for compact, high-torque axial flux designs.

Seamless integration with the system in mind

E-motor integration with inverter, gearbox, and cooling systems.
Support from concept to vehicle-level validation for customer-specific architectures.
Packaging, harness design, thermal management, and functional safety expertise.
Custom mechanical, electrical, and thermal interfaces for each project.
Proven collaboration with premium OEMs and Tier 1s from prototype to series.