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Victrex E-motor solutions

PEEK SOLUTIONS DESIGNED TO IMPROVE RELIABILITY AND EFFICIENCY IN HIGH-VOLTAGE E-MOTORS 
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VICTREX PEEK SOLUTIONS FOR THE NEXT GENERATION ELECTRIC VEHICLES

Future mobility requires new approaches in design and sustainable material selection, driven by the need to increase vehicle range, reduce cost, enhance driving and charging experience – all with without compromising on reliability and safety.
Explore how VICTREX™ PEEK based e-motor solutions can outperform traditional materials in 800V motors and support your sustainability goals, and why collaborating with our dedicated e-mobility team can help accelerate your e-motor projects.

VICTREX XPI Polymer Magnet wire insulation
APTIV Film High-performance slot liners

VICTREX XPI™ PEEK Magnet Wire Insulation

To cope with higher voltage (800V) platforms and SiC and GaN switching technologies, requirements for e-motor insulation become more demanding. The new VICTREX XPI™ polymer grades are designed to meet all extrusion wire manufacturing processing needs and offer a combination of excellent electrical, mechanical, high-temperature and chemical resistance performance for e-motor magnet wire to enable reliable insulation.
High-voltage electric motor with VICTREX XPI PEEK magnet wire coating

A unique combination of properties - specifically designed to solve the demanding challenges in high-voltage e-motor insulation

The new VICTREX XPI™ polymer grades are designed to meet all extrusion wire manufacturing processing needs and offer a combination of excellent properties for high-voltage e-motor magnet wire to enable reliable insulation performance, extended vehicle range, reduced cost and faster charging for high-performance motors.

 

Chem

Chemical Resistance

Outstanding resistance to chemical attack from a wide range of materials including ATFs and dielectric fluids even in 800V vehicle voltage systems, supporting reliable performance

Electrical

Electrical Performance

Proven dielectric properties with high breakdown voltage, partial discharge inception voltage (PDIV), resistivity, low permittivity and loss etc.

Temperature Resistance

Excellent thermal endurance and stable operation from -40°C up to 260°C 

Text

Mechanical Strength

Dedicated range of product grades with excellent strength, stiffness and ductility properties to meet the requirements in high power density e-machines

Text

Recyclability

VICTREX XPI PEEK polymer is REACH compliant, recyclable and solvent-free, eliminating the need for hazardous solvents used in enameled magnet wires

Thermometer

Thermal Conductivity

VICTREX XPI PEEK polymer has around 2x the thermal conductivity of other super engineering polymers (e.g. PI)

E-book: VICTREX XPI PEEK polymer for magnet wire coating
interactive e-book
Design Freedom and Reliability

Optimise your motor design and increase efficiency and vehicle range with state-of-the-art winding technologies.

Download e-book
VICTREX XPI PEEK magnet wire coating animation
Technical Animation
Next level e-motor performance in 800V systems
Increase e-motor reliability and accelerate your time to market leveraging the Victrex e-mobility ecosystem.
Watch our technical animation
James Bonnett, Programme Leader
video case study

Optimising e-motor performance with PEEK magnet wire insulation 

E-mobility program leader James Bonnett talks about the value of VICTREX XPI and the Victrex e-mobility ecosystem helps accelerate our customers' development times.

Watch video
Video
Victrex' e-mobility ecosystem
Learn more about the dedicated approach to deliver high-performing, sustainable e-motor solutions.
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John Grasmeder
blog
High-performance polymers explained

Our Chief Scientist introduces you to the world of PEEK and PAEK.

Read blog
What is PEEK - video
video

What is PEEK?

You're not familiar with PEEK? Here's your 3-minute introduction to one of the highest-performing polymers in the world

Watch  video
FAQ

Frequently Asked Questions: VICTREX XPI™ PEEK (PolyEtherEtherKetone) Magnet Wire Insulation for 800V E-Motors

Technical Performance Questions
PEEK magnet wire breakdown voltage after thermal aging
Testing demonstrates VICTREX XPI™ PEEK maintains enhanced breakdown voltage and PDIV performance after thermal cycling, showing improved retention compared to traditional enamel coatings in long-term reliability tests (with little or no loss of thickness due to thermal ageing, unlike thick enamel coatings).
PEEK vs enamel magnet wire coating thickness comparison
While VICTREX XPI™ typically ranges from 80-300 microns (vs 5-100 for enamel), its electrical properties deliver effective insulation performance per unit thickness - important for 800V reliability.
What is PEEK magnet wire PDIV rating for 800V electric motors?
VICTREX XPI™ PEEK is a high-performance thermoplastic polymer that delivers higher PDIV (Partial Discharge Inception Voltage) performance than traditional PAI (Polyamideimide) enamel coatings - important for 800V systems using fast-switching SiC (Silicone Carbide or GaN (Gallium Nitride) inverters. Testing shows stable PDIV performance even after thermal cycling, with no coating shrinkage.
What temperature can PEEK insulated magnet wire withstand?
VICTREX XPI™ PEEK operates reliably from -40°C up to 260°C with a Class 220°C rating (vs. 180°C for PAI enamel). Combined with 2x thermal conductivity compared to some engineering polymers, this enables enhanced motor performance in demanding applications.
Processing & Manufacturing Questions
PEEK magnet wire compatibility with varnish impregnation resin
Testing with leading resin suppliers confirms compatibility between VICTREX XPI™ and many standard varnishes/potting compounds.
How to strip PEEK coated magnet wire mechanical laser methods
Both mechanical and laser stripping methods have been proven to work effectively with VICTREX XPI™ and we have supporting evidence for this.
Can PEEK wire coating work with hairpin winding process?
Yes - VICTREX XPI™ PEEK is optimised for hairpin and wave winding with at least 2x tighter bending radius capability vs enamel. Thermal cycling data on hairpin configurations confirms reliable performance.
Chemical Resistance & Durability Questions
PEEK wire insulation resistance to ATF oil cooling fluids
VICTREX XPI™ PEEK withstands a wide range of ATFs and dielectric fluids at 180°C for up to 2,000 hours with retention of electrical properties - validated by OEM oil experts.
Cost & Efficiency Questions
PEEK magnet wire cost benefit analysis electric vehicle range
Simulations and tests show an improved motor efficiency potential with VICTREX XPI™ PEEK polymer vs enamel, translating to cost savings through battery size reduction and/or extended range opportunity. Also due to high frequency of pin holes in enamel wires there is significant scrap reduction potential for XPI coated wires. Contact our team to learn more!
PEEK vs enamel wire coating total cost ownership(TCO)
While initial costs differ, VICTREX XPI™ PEEK polymer delivers value through potential for efficiency gains, extended range capability and increased power density, as well as scrap rate reduction.
Sustainability Questions
Is PEEK magnet wire coating environmentally friendly and sustainable?
Yes - VICTREX XPI™ PEEK polymer uses up to 60% less energy than enamel coating processes, eliminates hazardous solvents, and is fully recyclable.
PEEK wire coating VOC (volatile organic compounds) emissions environmental compliance automotive
VICTREX XPI™ contains no hazardous solvents, simplifying compliance and supporting OEM (original equipment manufacturer) sustainability goals. Victrex has SBTi approved targets for net-zero emissions by 2050.
Supply Chain & Support Questions
Technical support PEEK magnet wire coating implementation

Victrex provides custom formulations, processing support, electrical testing data, and e-motor modelling - backed by 40+ years of PEEK expertise.

Source: eBook pages 13-14

VICTREX XPI PEEK availability lead time global supply
As the #1 global PEEK producer with integrated supply chain and warehouses strategically located worldwide, Victrex provides reliable supply and short lead times for automotive programs.
Industry-Specific Questions
PEEK magnet wire testing validation automotive OEM certification
VICTREX XPI™ is protected by multiple patents and validated through our e-mobility ecosystem including partnerships with research institutions. The manufacture of VICTREX XPI PEEK polymer is IATF16949 certified.
PEEK wire insulation SiC (silicon carbide) inverter compatibility
PEEK's electrical properties make it well-suited for high dv/dt SiC and GaN systems in 800V powertrains, providing the reliability these fast-switching technologies require.
APTIV Film PEEK slot liners

Advanced APTIV™ film electrical insulation for e-motor slot liners

APTIV™ film electrical insulation solutions provide improved thermal conductivity over traditional laminates. With a thin film format they can help e-motor manufacturers increase copper density and improve thermal management. 
Peek ploymer
APTIV film slot liners enabling increased copper density in high power density e-motors

Greater power density

  • 40% thinner film format enabling
  • 2% increased copper content and
  • 5% increased continuous torque output

in a same size motor

APTIV film slot liners enabling improved thermal management in high power density e-motors

Improved thermal management

The excellent thermal conductivity of APTIV™ film enables improved thermal management and reduction of peak winding temperatures by 2-3 °C vs. Meta-Aramid/PET laminates

APTIV film slot liners enabling reduction of e-motor bill of material in high power density e-motors

Cost-effectiveness

offering a potential reduction of 6 USD per e-motor in a smaller motor with same power output by reducing axial length (less utilisation of rare earth magnets)

All statements based on simulation work courtesy of Motor Design Ltd. using Motor-CAD v9.3.1 -  replacing 250 micron Meta-Aramid/PET laminates with 150 micron APTIV film slot liners
PEEK-Based APTIV film slot liners for 800V e-motor insulation
NEW interactive e-book

APTIV film slot liners for high-voltage e-motors

Explore key material properties, extensive comparative data vs. traditional laminates, quantified benefits and much more in the 24-page interactive e-book!

Download e-book
Magnet wire insulation
webinar recording

The impact of advanced PEEK slot liner insulation on high power density e-motors

Dive into technical details and comparative test results in this webinar recording

Watch webinar recording
VICTREX PEEK based APTIV film rolls in a variety of thicknesses
aptiv films
Learn more about APTIV films
All the benefits of VICTREX™ PEEK polymer in a thin-film format
Find out more
gererator
Blog
The quest to cut e-motor cost by adopting new material solutions
Our e-mobility programme leader James Bonnett looks into challenges and opportunities for e-motor manufacturers.
Read blog article
APTIV film slot liners enabling increased copper density in high power density e-motors
animation
Increase copper fill factor or save cost on your bill of material
See how APTIV™ film slot liners can help increase power output of a same-sized e-motor or reduce its size and save on your bill of material.
Watch video

Why Victrex?

From the commercialisation of PEEK over 40 years ago, Victrex has continually pioneered new PAEK-based polymer solutions that have transformed markets, delivering global impact in the toughest environments.

Our commitment to innovation shapes everything we do, from 10,000 feet below the sea to 40,000 feet in the air. We aim to solve today’s toughest challenges and look to push design boundaries for tomorrow. We are engineers, scientists, designers and market specialists, all focused on bringing transformational solutions to market that address world material challenges. That’s our team, over 900 people every day helping to make a world of difference.
video

Accelerate your e-motor projects leveraging Victrex's e-mobility ecosystem  

Rapid response, deep market insight, custom formulations and dedicated support to accelerate your time to market
Watch 3-minute video
infographic

Sustainability is at the top of our agenda

Explore our infographic to see our ambitious path to net zero and how VICTREX PEEK supports a sustainable approach in magnet wire insulation vs. enamel.

View infographic
James Bonnett, Programme Leader
video case study
Optimising e-motor performance with PEEK magnet wire insulation
E-mobility program leader James Bonnett talks about the value of VICTREX XPI and the Victrex e-mobility ecosystem helps accelerate our customers' development times.
Watch video case study

VICTREX™ PEEK solutions for e-mobility

VICTREX PEEK insulated bearings

Electric Motor Bearing Insulation

Reliable insulation of bearings is key to ensure efficient performance over the component lifetime. Using VICTREX™ PEEK to overmould bearings helps address reliable electrical insulation of large or small bearings and potentially reduces component cost.

contact us to discuss your bearing insulation requirements
Battery Bus Bars

Battery Bus Bars

Bus bars are a safety critical component and key for system efficiency & reliability in EV batteries, e-motors or power electronics. They need to perform in the most demanding environments. VICTREX™ PEEK offers a combination of excellent temperature performance and electrical properties to ensure durability as well as extended flammability resistance. 

Contact us to discuss your bus bar needs

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VICTREX PEEK polymer
technical guide
Check out our technical guide to PEEK extrusion processing for further support.
Download extrusion guide
Scientist looking into a microscope
flyer
VICTREX PEEK polymer offers excellent resistance to a wide range of chemicals.
Download chemical resistance flyer
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SHAPING FUTURE PERFORMANCETM

From the invention of PEEK over 40 years ago, Victrex has continually pioneered new PAEK-based polymers, materials and solutions that have transformed markets, delivering global impact in the toughest environments.

We bring transformational & sustainable solutions that address world material challenges every day.

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