More Copper. More Cooling.
Copper MIM for E-Mobility and Power Electronics
From motor coils to pin fin plates
We design and supply copper components manufactured via Metal Injection Molding: high-density motor coils and AME MIM copper pin fin plates for demanding automotive and industrial applications.
Explore MIM motor coils below!
>>> Click here to get information about AME MIM pin fin!
One process chain for EM & thermal performance
MIM motor coils boost the electromagnetic side of your drive, while AME MIM copper pin fin coolers address the thermal limits of your power modules. 3D printing is used for fast prototypes with matching material families, so your designs scale seamlessly into series MIM production.
Copper coils made by Metal Injection Molding
With Metal Injection Molding we transfer the design freedom of injection molding to high-purity copper – including near 100 % slot fill and full 3D cross-section freedom.
For early development stages, we manufacture the same geometries using 3D printing with material grades matched to the later MIM series. This allows you to validate form, fit and thermal behaviour on single parts or small batches – and then roll out the very same design to high-volume MIM production.
Maximum copper density in the stator slot – less loss or more power in the same volume.
Cross-sections optimized for AC losses, thermal paths and field distribution.
MIM copper with electrical and thermal properties comparable to solid copper.
Multi-layer windings within one coil body – reproducible and geometrically precise.
Example of a MIM axial-flux coil
In an axial-flux motor most copper losses occur close to the rotor disc. With a MIM-manufactured single-turn spiral coil, the conductor cross-section can be shaped individually for each turn: thicker near the rotor plane, thinner further away – while keeping the copper area (and thus the electrical cross-section) constant. The lower turns act as a thermal buffer with short conduction paths into the cooled disc and stator structure, whereas the upper turns offer increased surface area for heat transfer into potting or surrounding media. This way, hot spots are reduced without sacrificing current capability or increasing resistance.
AME MIM copper pin fin cooling for power electronics
Together with AME we provide copper MIM pin fin coolers that combine the thermal conductivity of classical copper with the design freedom of near-net-shape injection molding. High-density sintering leads to approximately 99 % dense copper, keeping porosity and leakage under control for demanding in-vehicle applications.
What AME MIM pin fins enable
- Three-dimensional pin fin topologies with locally adjusted pin height, shape and density.
- Integrated flow distribution features and simple manifolds in one copper part.
- Fine tuning of the cooling vs. pressure-drop trade-off for a given coolant circuit.
- Automotive-ready concepts targeting vibration, thermal cycling and coolant chemistry.
Typical use cases
- Traction inverter baseplates with pin fin fields aligned to IGBT/MOSFET layouts.
- On-board chargers and DC/DC converters with compact, integrated flow paths.
- Industrial power converters and compact liquid-cooled supplies beyond automotive.
For a deeper dive into material, porosity, mechanical and cost aspects: visit the dedicated AME MIM pin fin page.
Where copper MIM makes the biggest difference
MIM coils and AME MIM pin fin coolers are a strategic upgrade wherever power density, efficiency, weight and thermal limits define the product.
Drones & airborne systems
For electric flight, every watt and every gram counts. MIM coils let you pack more copper and better thermal paths into very tight stator geometries.
- Professional UAVs – higher efficiency and longer flight time.
- HALE / long-endurance drones – optimized AC-loss behaviour at high electrical frequencies.
- eVTOL / multirotor – high power density in compact, HV-robust motors.
800 V traction motors for cars & trucks
Modern traction drives push voltage, current and temperature windows to the limit.
- Near-full slot fill for higher torque and continuous power in the same space.
- 3D geometry for HV-robust designs at 800–1200 V with reduced partial discharge risk.
- Better thermal contact to the lamination stack and cooling system.
Compact two-wheeler & powersports drives
Motorcycles, scooters and powersports vehicles are extremely space constrained.
- Maximized copper utilization for high torque in small motors.
- Improved continuous performance thanks to better thermal conduction.
- Coils that follow unconventional stator geometries in sporty designs.
Industrial servo motors
Servo drives run many hours at high utilization and demand precise torque control.
- Lower copper losses at continuous load for better efficiency.
- More compact machines at the same torque level.
- Tailored AC-loss behaviour for high-speed operation.
Generators & wind turbine drives
In generators and wind applications, lifetime and thermal stability dominate the design space.
- More homogeneous winding temperatures reduce thermal fatigue.
- Higher copper utilization for improved efficiency over long operating hours.
- 3D-optimized conductor paths for special topologies (e.g. axial-flux generators).
One technology base, many platforms.
Once the MIM design rules are established, you can derive families of motors and coolers across voltage classes and sectors – with re-usable simulation and manufacturing know-how.
From CAD concept to series production
Concept
Geometry & simulation
You provide the motor or module layout; we develop the matching MIM geometry, assess slot fill, losses and thermal performance, and align it with manufacturability.
Prototyping
3D printed samples & validation
We produce functional prototypes using 3D printing with material systems matched to the later MIM copper. This enables fast iterations while keeping the path to series open.
Series
Industrialized & scalable
Once the design is frozen, it is transferred to full MIM tooling and high-volume production – from a few thousand parts to million-unit volumes.
Request a project assessment!
Interested in understanding how much additional power density or cooling performance MIM components could unlock in your designs? Send us a short description or a simplified layout by email:
For technical inquiries and project requests, you may also use the following form: