Why PEEK Is Ideal for EV Motors?

Introduction

Polyether Ether Ketone (PEEK) is a high-performance engineering plastic first developed by ICI in the UK in 1978 and industrialized by Victrex in the early 1980s. Over the years, PEEK has proven itself across aerospace, electronics, and automotive applications due to its outstanding mechanical, thermal, and electrical properties.
Today, as electric vehicles (EVs) and high-efficiency industrial drives evolve, PEEK plays a critical role in advancing electric drive system design, offering enhanced reliability, thermal stability, and lightweight advantages.

Key Applications of PEEK in Electric Drive Systems

Core PEEK Applications

1. Stator Insulation System

PEEK films and molded parts—such as Ajedium™ PEEK slot liners and KetaSpire® PEEK magnet wire insulation—enable thinner insulation, improving the motor slot fill factor up to 75% or more. This allows for more copper wiring, boosting torque and power density while enhancing heat dissipation—critical for high-voltage platforms (800V and above).

2. Rotor and Transmission Components

PEEK and carbon-fiber-reinforced PEEK are widely used in bearing cages, gears, and lightweight structural parts. Their excellent wear resistance and strength support high-speed rotation under heavy loads while reducing component weight, thus improving overall system efficiency.

3. High-Voltage Connectors and Support Systems

PEEK-based materials such as Amodel® PPA and Ryton® PPS are used in busbars and electrical connectors. Their high dielectric strength and mechanical integrity ensure reliable performance in high-voltage drive systems.

Why PEEK Is Preferred in Electric Drives

• Superior Heat Resistance: Maintains stability up to 250°C, ideal for prolonged high-temperature operation.

• Excellent Electrical Insulation: Dielectric strength above 2300V ensures safety in high-voltage environments.

• Outstanding Mechanical Strength: Resists wear, vibration, and mechanical fatigue in dynamic conditions.

• Chemical and Moisture Resistance: Stable in harsh or corrosive environments.

• Flame Retardant and Self-Extinguishing: Improves overall system safety.

Challenges and Considerations

While PEEK is an excellent material, it faces certain challenges:

• High Cost: Its production cost is higher than metals or standard plastics.

• Difficult Processing: Requires specialized equipment for molding, machining, and welding.

• Aging and Long-Term Stability: Prolonged exposure to heat and humidity may cause performance degradation; material modification is often needed for optimization.

Real-World Applications

• Mavel Power Systems used Syensqo's Ajedium™ and KetaSpire® PEEK for slot liners and magnet wire insulation in high-voltage motors developed for luxury sports cars.

• Jateng Electric and Victrex achieved mass production of PEEK flat wire insulation, now used by automakers such as Lotus, BMW, Audi, Mercedes-Benz, and NIO.

Future Outlook

With the rapid growth of electric vehicles, robotics, and high-efficiency drives, the application scope of PEEK is expanding. Advances in composite PEEK formulations and large-scale manufacturing will further reduce costs and enhance performance, making PEEK an increasingly vital material in next-generation electric drive systems.