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Heavy-Duty Motors Use Printed Windings to Deliver High Efficiency and Reliability

Feb. 28, 2025

A new series of compact, cool-running HD motors from Infinitum, which feature printed windings and an integrated VF drive, target mission-critical HVAC fan and pump systems.

Lee Goldberg

Related To: Electronic Design

Infinitum’s heavy-duty variant of its high-efficiency air-core motor series are designed specifically to address the demanding requirements of mission-critical HVAC fan and pump applications, while reducing energy consumption, emissions, noise, and waste.

Like other Infinitum motors, the Aircore Heavy Duty motor replaces the copper-wound iron stator found in conventional motors with a lightweight, printed-circuit-board (PCB) stator that uses 66% less copper and is 10X more reliable. It also features an integrated variable-frequency drive that powers heavy loads with up to 25% more efficiency.

When combined with the AirCore’s unique printed winding technology, these motors offer a compact form factor that’s up to 60% shorter in length and up to 50% lighter than conventional motor and drive solutions.

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The motor, built with a rugged exterior for protection against dust, dirt and water, is designed to operate reliably in harsh outdoor or wet environments, maintaining high efficiency across a wide range of loads.

Available immediately with models that span a wide range of power outputs, Aircore Heavy Duty motors can be configured with bearing, NEMA MG1 shaft, and frame sizes to meet the needs of mission-critical applications, such as HVAC equipment, vertical-inline pumps, and Coolant Distribution Units (CDUs) used in data centers.

The Aircore family’s modular architecture offers several additional advantages:

Customers can use Infinitum’s selection of off-the-shelf options to create a “right-sized” solution that meets their application's exact HP/RPM requirements.
The Aircore Heavy Duty series supports a wide variety of communication protocols, including Modbus RTU, BACnet MSTP, and Analog.
The integrated controller’s driver software enables users to configure and fine-tune operational parameters, while monitoring motor performance and other key parameters.

To learn more about the Aircore Heavy Duty, visit Infinitum’s Product Applications Page or download a product brochure.

About the Author

Lee Goldberg | Contributing Editor

Lee Goldberg is a self-identified “Recovering Engineer,” Maker/Hacker, Green-Tech Maven, Aviator, Gadfly, and Geek Dad. He spent the first 18 years of his career helping design microprocessors, embedded systems, renewable energy applications, and the occasional interplanetary spacecraft. After trading his ‘scope and soldering iron for a keyboard and a second career as a tech journalist, he’s spent the next two decades at several print and online engineering publications.

Lee’s current focus is power electronics, especially the technologies involved with energy efficiency, energy management, and renewable energy. This dovetails with his coverage of sustainable technologies and various environmental and social issues within the engineering community that he began in 1996. Lee also covers 3D printers, open-source hardware, and other Maker/Hacker technologies.

Lee holds a BSEE in Electrical Engineering from Thomas Edison College, and participated in a colloquium on technology, society, and the environment at Goddard College’s Institute for Social Ecology. His book, “Green Electronics/Green Bottom Line - A Commonsense Guide To Environmentally Responsible Engineering and Management,” was published by Newnes Press.

Lee, his wife Catherine, and his daughter Anwyn currently reside in the outskirts of Princeton N.J., where they masquerade as a typical suburban family.

Lee also writes the regular PowerBites series.