Vacuum Potting of Stators: A Technology That Takes Electric Motor Life and Performance to a New Level

The demands on modern electric motors are constantly growing. Higher performance with smaller dimensions, extreme reliability and the ability to work in demanding environments are required. The answer to these challenges is the vacuum potting technology of the stator winding at SOPU. What is its magic and why is it worth investing in it?

In the production of top-quality electric motors, precise winding alone is no longer enough. The key factor that determines whether a motor will last for years of trouble-free operation or fail at the first overload is the final treatment of the winding. While classic varnish impregnation has its place, for demanding applications we are switching to vacuum epoxy resin casting .

Why does the air have to go away?

Air is the enemy of a powerful engine. It acts as a thermal insulator (prevents cooling) and in a high-voltage area can be a source of so-called partial discharges, which gradually degrade the insulation.

At SOPO, we use advanced vacuum technology. The potting process takes place in a closed chamber where a vacuum is created. Thanks to this, we can:

1. Remove microscopic air bubbles from the depth of the winding.

2. Ensure perfect penetration of the resin even into the smallest gaps between the conductors and stator sheets.

3. Create a homogeneous whole (monolith) that has the same physical properties in all places.

4 main benefits that technology brings to customers

The vacuum process results in a stator that significantly outperforms conventional solutions. Here are the main reasons why more and more of our clients are turning to this technology:

1. Effective thermal management 🌡️

Epoxy resins have significantly better thermal conductivity than air. The cast stator acts as a thermal bridge – effectively transferring the heat generated in the windings towards the motor casing and cooling. The result? The motor does not overheat, can withstand higher current loads and operates more stably.

2. Mechanical resistance (Vibrations don't stand a chance) 🛡️

In demanding industrial operations or traction motors, vibrations and shocks are the order of the day. Potting fixes the conductors in one solid mass. This prevents the wires from rubbing against each other, which could otherwise lead to abrasion of the insulation and subsequent short circuits.

3. Perfect protection from the environment 💧

Moisture, dust, chemicals or metal shavings. The cast stator is virtually immune to these influences. This technology is therefore ideal for pumps, fans or motors operating in aggressive environments.

4. Noise reduction 🔇

The fact that the winding and stator bundle form a compact unit significantly reduces mechanical resonances. The motor is quieter in operation, which is a key parameter in many modern applications.

At SOPU we focus on quality without compromise

The implementation of vacuum potting technology requires state-of-the-art equipment and precise adherence to process parameters. At SOPU, we are proud to master this technology and offer it as a standard for projects where quality comes first.

Whether you are developing a new prototype or looking for a way to increase the reliability of existing products, our technology is ready.

Are you considering using potted stators in your project? Contact our sales department. We will be happy to discuss the technical options with you and propose the optimal solution.