A 375 kW (500 HP), 5000 RPM, brushless interior permanent magnet (IPM) motor, previously designed and optimized with high‐grade sintered NdFeB magnets, was redesigned using Nichia AL16C SmFeN (samarium‐iron‐nitride) magnets. The goal was to use the same design of stator while enhancing the rotor design by minimizing the magnetic material mass and creating unique magnet geometries to improve overall magnetic performance.

While both rotor options demonstrated consistent torque output, the injection molded SmFeN version exhibited twice the resiliency of the sintered NdFeB design under short‐ circuit stator conditions. Moreover, the injection molded SmFeN rotor simulations highlighted a cooling advantage over the sintered NdFeB version. In tandem with performance comparisons, a manufacturing assessment was also conducted, focusing on the ability to orient and saturate magnetic material in situ.

This analysis indicated a high likelihood of successful implementation for production. Tengam Engineering and Oak Ridge National Labs will speak on how injection molded IPM rotors, which utilize injection molded Nichia AL16C SmFeN magnets, can deliver improved performance while being more cost effective than conventional sintered magnet designs.