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Low Pressure Molding (LPM) |
Injection Molding |
Potting |
Conformal Coating |
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Encapsulation improves heat shedding from windings and shields against contaminants, reducing noise/vibration and extending motor efficiency and life. |
Suitable for low-heat, simple motor designs where environmental sealing is needed but thermal extraction and structural integration are minimal. |
Poor fit because high pressures and temperatures are incompatible with assembled motors and internal components. |
Offers robust protection against contaminants, but added mass, slow processing, and limited heat dissipation reduce suitability for modern motor designs. |
Poor fit, as conformal coatings offer no structural restraint, vibration damping, or meaningful heat transfer for motor assemblies. |
Motor Assemblies
Motor assemblies often have the same set of failure drivers: heat buildup in windings, vibration-driven wear and wire movement, and exposure to water, oil, dust, and debris. X2F enables molded encapsulation and integrated protection around motor internals such as coils, windings, sensors, leads, and connectors. Designed to improve robustness while keeping production practical and repeatable.
Encapsulation Around Coils, Windings, Sensors, Leads, and Connectors
X2F is well suited for precise encapsulation around motor features, including coils and windings, embedded sensors, leads, and connector transitions. This supports controlled coverage and geometry around sensitive regions without relying on multiple secondary protection steps.
Heat Management for Windings and Coils
Motor performance and life are frequently limited by how effectively heat leaves the windings. X2F supports the use of thermally conductive materials to move heat out of coils and windings, enabling designs that address thermal constraints without adding separate thermal assemblies.
Vibration and Shock Resistance Through Molded Lock-In
Vibration and shock can drive wire movement, fretting, and fatigue at terminations. X2F’s molded structures can lock in coils, sensors, and wires to reduce relative motion, helping improve durability in vibration-heavy environments.
Environmental Sealing for Harsh Operating Conditions
Motors often need reliable sealing against water, oil, and dust. X2F forms robust, repeatable seals as part of the molded structure, supporting consistent protection without seal stacks and multi-part sealing schemes.
Controlled Processing for Sensitive Components
Encapsulation processes can damage motor internals if temperature and pressure aren’t well controlled. X2F is designed to limit processing stress on components through controlled temperature and pressure This supports sensitive coils, sensors, and interconnects.
Production Practicality and Cost Efficiency
X2F is designed for fast cycles and repeatable results, supporting scalable production. By using material efficiently and reducing added parts, it can improve overall practicality and help control material and operational cost while supporting long-term reliability in harsh conditions.