AeroStator Core™ Technology

Patented Motor Technology

Six patented technologies in one motor architecture — the highest torque-density electric motor available, built for drones, UAVs, aviation, EVs and robotics.

1.5×
Higher magnetic field vs radial
~75%
Copper fill factor vs 35% round wire
15
N·m/kg specific torque density — proven
IP65
Optional fully-sealed construction

Six technologies, one motor

Every eMotres motor integrates the same six innovations — four production-proven, plus two patented firsts at the coil — that together push torque density beyond what conventional designs can achieve.

Tangential Magnet Polarization
1

Tangential Magnet Polarization

Flux concentration beyond standard Halbach arrays — no adhesive, easy re-magnetization.

1.5× higher magnetic field
The tangential magnet arrangement concentrates flux more effectively than standard radial or Halbach arrays — more torque from the same magnet volume.
No adhesive required
Magnets are mechanically constrained — no epoxy. Easy removal for re-magnetization or field replacement without specialist tooling.
Best torque-to-weight ratio
Inrunner topology with tangential magnets outperforms outrunner motors of equivalent diameter and mass in specific torque (N·m/kg).
Rectangular Copper Wire
2

Rectangular Copper Wire

~75% slot fill factor vs ~35% for round wire — lower resistance, higher current density, less heat.

~75% fill factor vs ~35% round wire
Rectangular (flat) wire fills the slot cross-section far more efficiently. More copper per slot means less resistance for the same winding geometry.
Lower winding resistance = less heat
Lower resistance directly reduces I²R copper losses. The motor runs cooler at the same output, or makes more power at the same temperature limit.
Higher current density
The same slot area carries significantly more current, enabling higher peak torque without increasing motor size or weight.
High-Efficiency Cooling System
3

High-Efficiency Cooling System

Yoke cutouts give cooling the shortest possible path from winding to ambient — air or liquid.

Shortest thermal path
Cutouts in the yoke directly above each coil eliminate the thick iron barrier between winding and cooler. Heat path is 2–5× shorter than a standard stator.
2× larger cooling surface
The cutout geometry doubles the effective contact area between the winding and the cooling medium — air or liquid. More surface = faster heat transfer.
Air or liquid cooling
The same thermal architecture works with both media — centrifugal fan for air, manifold on the yoke cutouts for liquid. No redesign between options.
Single Layer Winding
4

Single Layer Winding

2× fewer coils than standard designs — less winding time, lower cost, higher reliability.

2× fewer coils than standard
A concentrated winding topology with half the coil count of a standard distributed winding for the same slot/pole configuration. Less winding time, lower labour cost.
Simpler assembly
Fewer coils means fewer connections, fewer failure points and simpler quality control. Each coil is individually accessible for inspection and replacement.
Lower production cost
Reduced coil count cuts both material and assembly time. Combined with rectangular wire’s high fill factor, the motor is cheaper to wind and more reliable in service.
Copper & aluminium foil-coil prototypes
5

Foil Coil Technology

In development now

Copper & aluminium foil-coil prototypes

Single-piece flat-sheet coil — zero welded joints, eliminated eddy-current loss points, increased fill factor.

Made from
1 flat sheet
Welded joints
Zero
Cut variants
2 types
Process
3 steps
Tooling
Standard
Eddy sources
Eliminated

Why it matters: No welds means fewer eddy-current loss points, and standard cut-and-bend tooling makes the coil mass-production ready.

Al₂O₃ ceramic insulation plates
6

Ceramic Coil Insulation

Al₂O₃ ceramic insulation plates

3-sided heat transfer — ≥100× higher thermal conductivity vs polymer. Enables fully sealed IP65 construction.

Plates per slot
3
Material
Al₂O₃ / AlN
Thickness
0.1–0.5 mm
k (Al₂O₃)
≥25 W/m·K
k (AlN)
≥140 W/m·K
vs polymer
<0.2 W/m·K

Why it matters: Three-sided coupling (vs two-sided) insulates and conducts heat at once, enabling higher current density at a lower coil temperature.

IP65 sealing

One architecture, two cooling options

The same sealed stator works with air or liquid cooling without a redesign — choose the medium that fits the duty cycle.

💨 Air cooling

  • Centrifugal fan draws air through the yoke cutouts
  • Effective for most drone and aviation applications
  • Simpler installation — no liquid lines or manifolds
  • Suitable for open or IP65-sealed configurations
  • Operational range up to ~60 °C ambient

💧 Liquid cooling

  • Coolant manifold attached directly to the yoke cutouts
  • 2–5× lower thermal resistance vs air cooling
  • Enables continuous high-power operation
  • Required for motors above 10 kW continuous
  • Compatible with water-glycol or oil circuits

IP65: complete protection against dust ingress and low-pressure water jets from any direction — available as a factory option on all CIANO motors.

Intellectual property

Patent portfolio

9 granted / registered · 4 pending · 6 jurisdictions · EPO inventive step confirmed.

✓ Granted / registered

PCT
PCT/IB2023/057129
International · Jul 12 2023
PCT
PCT/IB2025/058444
Ceramic insulation · Aug 21 2025
PCT
PCT/IB2025/060049
Coil for electric machine · Oct 6 2025
SI
SI No. 26604
Slovenia · Short-term patent · Jul 31 2025
CN
ZL 202390000194.8
China · Utility model · May 2 2025
DE
DE 21 2023 000 117
Germany · Utility model · Oct 18 2024
FR
FR No. 24 07270
France · Utility certificate · Jul 11 2025

⏳ Pending / under examination

PCT
PCT/IB2026/053894
Core AeroStator Core™ topology · Apr 20 2026
ES
ESU202490013
Spain · In examination
IN
202517116950
India · Filed Nov 25 2025
🏆 EPO inventive step confirmed

The European Patent Office independently validated the novelty and inventive step of the AeroStator Core™ topology.

See the technology in action