H3X, a well-funded startup specializing in high-power density electric motors, introduced its latest product, the HPDM-180R. Like previous products from H3X, this latest high-performance motor combines 3D printing, cutting-edge materials, and intelligent design to deliver a continuous output of 180 kW and a peak efficiency of 94.6%, all in a 16 kg frame.
After closing an oversubscribed $20M funding round last August, H3D has quickly become a leader in electric propulsion by focusing on disruptive manufacturing methods and high-performance engineering. The company’s commitment to innovation is evident in its adoption of additive manufacturing and developing tightly integrated motor systems that go beyond conventional designs.
AM in the HPDM-180R motor
The HPDM-180R is a fully integrated system with an inverter and a reduction gearbox designed for maximum efficiency and minimal footprint. Its compact size and high power density make it ideal for demanding applications like electric aircraft, high-speed marine vehicles, and advanced industrial systems. By reducing shaft speed to 3,000 RPM through its integrated planetary gearbox, the HPDM-180R is particularly well-suited for propeller-driven applications.
Another breakthrough is the motor’s integrated Silicon Carbide (SiC) inverter. These discrete SiC devices allow for ultra-high-density configurations and faster switching speeds. Coupled with an in-house-developed self-sensing rotor position algorithm, the inverter enhances overall motor responsiveness, efficiency, and reliability. Additionally, the system benefits from advanced common-mode filtering, which reduces electrical noise and further boosts performance.
H3D addresses thermal management through a structurally synergistic cooling jacket. This single component, manufactured through additive techniques, simultaneously cools the power electronics and the stator. This reduces weight and complexity and ensures seamless integration between the motor and inverter, which is rarely seen in conventional designs.
The integrated planetary gearbox features a compact 6.7:1 single-stage reduction, bringing the motor’s original 20,000 RPM speed down to a practical 3,000 RPM at the output shaft. This level of integration minimizes system weight and increases reliability while maximizing power output.
Capabilities and applications
The HPDM-180R delivers a continuous torque of 576 Nm and maintains its peak efficiency of 94.6% across various operating conditions. It operates at less than 800 VDC and is rated for altitudes up to 45,000 feet, making it ideal for airborne applications. Its operating temperature range spans from -40 to 60 °C, and it uses a liquid cooling system to ensure optimal thermal performance. With a diameter of just 224 mm and a length of 430 mm, the motor offers a compact solution that does not sacrifice power.
Due to its power density, reliability, and integrated design, the HPDM-180R is a versatile solution for multiple sectors. In the aerospace industry, it is ideal for electric vertical takeoff and landing (eVTOL) aircraft, hybrid-electric propulsion systems, and more electric aircraft architectures. It supports high-efficiency propulsion for ferries, electric boats, and racing vessels in marine environments. The motor also proves valuable in heavy industrial use, such as mining equipment, electric power generation, and large-scale HVAC systems.
H3X’s use of 3D printing plays a pivotal role in the evolution of the HPDM-180R. Additive manufacturing allows the company to produce complex, lightweight structures that were previously impossible or cost-prohibitive using traditional methods. This design freedom enables integrating cooling systems and structural components into a single unit, improving performance while minimizing size and weight.
