hofer powertrain

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

Development of IM, ASM, PSM, EESM, and AFM architectures
High-speed e-motor designs with integrated oil cooling for maximum thermal stability
Lightweight, compact solutions with optimized end-windings and superior power density
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.
Benchmarking different technologies, i.e. comparing a PSM Hairpin (800 V, ⌀280 mm, 900 Nm) with a PSM FLW (around 800 V, ⌀235 mm, 500 Nm).
Test bench validation (I.e. peak power in the range of 300 kW, torque above 300 Nm, and continuous power exceeding 180 kW) under controlled conditions.
Efficiency mapping (I.e. up to +84% continuous torque and +20% shaft speed improvements wirh Form Litz Wire compared to Hairpin; peak efficiencies over 96%).
Cost benchmarking revealing savings potential (I.e. up to 18% BOM reduction by shortening active length)

New winding technologies for higher efficiency

Form Litz Wire (FLW) winding with copper fill factors up to 65%, significantly reducing AC and PWM losses
Up to +84% continuous torque improvement and 25% more continuous power output compared to hairpin winding
FLW 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

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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):

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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.

E-Motor