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Explore our specialized thermal and EMI conductive resins engineered specifically for frameless brushless DC motors, harmonic drives, and integrated joint modules in advanced robotics.
As the global robotics paradigm accelerates toward mass-manufactured bipedal humanoids, robotic actuator density has emerged as the critical bottleneck defining payload capacity, battery endurance, and operational longevity.
Modern humanoid robots require anywhere from 28 to over 50 degrees of freedom (DoF). Every joint—from dynamic 3-DoF hip and shoulder assemblies to compact 1-DoF knee and elbow rotary actuators—relies on ultra-compact, high-torque frameless brushless permanent magnet synchronous motors (PMSM).
To deliver explosive explosive torque for bipedal balancing, dynamic walking, and heavy payload manipulation, these motors are pushed to their continuous thermal limits. Traditional air cooling is physically unviable within sealed robotic limb housings. Heat trapped within the stator windings induces thermal runaway, accelerates winding varnish insulation degradation, and risks irreversible demagnetization of NdFeB permanent magnets.
Conductive epoxy resin encapsulation has shifted from an optional enhancement to a non-negotiable architectural requirement. By replacing air voids within the stator slot with thermally conductive potting compound, engineers establish direct thermal conduction paths from internal copper coils to outer aluminum skeletal chassis.
Potting stator windings with thermal conductive epoxy (1.5–3.5 W/m·K) dramatically lowers thermal resistance, enabling 30–40% higher continuous RMS current without exceeding Class H (180°C) limits.
Bipedal walking and jumping generate severe cyclic mechanical shocks up to 50G. Polymeric encapsulation bonds all stator laminations and copper coils into a monolithic solid block, eliminating coil friction and fatigue.
Hermetic potting protects sensitive internal electronics from atmospheric moisture, dust, industrial oils, and mitigates high-frequency electromagnetic interference produced by adjacent GaN/SiC power bridges.
Formulating encapsulation resins for robotic joint motors demands a multi-parameter balance between rheology, thermal conductivity, dielectric reliability, and thermal mechanical expansion.
Humanoid joint motors utilize high-slot-fill hairpin or concentrated winding configurations with wire spacing under 0.1 mm. Standard viscous resins create micro-voids, creating localized thermal hotspots and partial corona discharge.
Songxi's formulated conductive epoxies utilize surface-treated sub-micron spherical ceramic particles ($\mathrm{Al_2O_3}$ / $\mathrm{AlN}$ / $\mathrm{BN}$) combined with reactive diluent matrices. This achieves an initial mixed viscosity below 2,500 mPa·s at 25°C, ensuring rapid, 100% void-free vacuum impregnation into the deepest stator slot channels.
Mismatch between the copper windings ($\mathrm{CTE} \approx 16.5 \times 10^{-6}/\text{K}$), silicon steel laminations ($\mathrm{CTE} \approx 12 \times 10^{-6}/\text{K}$), and the potting resin causes internal shear stress, leading to delamination and micro-fractures under extreme thermal cycling (-40°C to +150°C).
Our formulations deliver a finely engineered CTE ($\alpha_1 135^\circ\text{C}$), ensuring zero shrinkage stress and long-term joint motor integrity across millions of operational cycles.
| Performance Metric | Standard Unfilled Epoxy | Songxi SX-8800 Robotic Potting Grade | Direct Impact on Humanoid Robot Joint |
|---|---|---|---|
| Thermal Conductivity (W/m·K) | 0.20 – 0.25 W/m·K | 1.80 – 3.20 W/m·K | Reduces stator winding hotspot temperature by up to 38°C under continuous load |
| Viscosity @ 25°C (Mixed) | 8,000 – 15,000 mPa·s | 1,800 – 2,800 mPa·s | Enables 100% deep slot fill in hairpin windings without air entrapment |
| Dielectric Strength (kV/mm) | 16 – 18 kV/mm | ≥ 25 kV/mm | Completely eliminates high-voltage partial discharge from 800V silicon-carbide PWM spikes |
| Glass Transition Temp (Tg) | 90 – 105 °C | 140 – 160 °C | Maintains mechanical structural rigidity during continuous stall torque conditions |
| Flame Retardancy | HB | UL 94 V-0 (0.8mm) | Meets critical aviation and industrial functional safety standards (ISO 13849) |
From high-power lower-limb locomotion joints to sub-miniature dexterous finger motors, discover how tailored epoxy chemistries solve mission-critical robotic challenges.
Lower limb joints experience continuous impact forces up to 300 Nm. Our thermally conductive potting compound solidifies the stator iron core and coil assembly into a fracture-resistant structure, preventing coil insulation abrasion under dynamic load shocks.
Robotic hands pack 5 to 12 micro brushless or coreless motors into human-scale palms. Space constraints prevent heat sinks. High-flow epoxy acts as an internal heat bridge, transferring heat to the outer titanium/aluminum skeletal finger structures.
Encapsulation ensures zero oil/lubricant ingress from harmonic or cycloidal gearboxes into motor windings. The chemically inert polymer barrier resists synthetic grease contamination and polyalphaolefin (PAO) lubricants over 100,000+ hours.
Modern humanoid joints integrate motor control units (MCU), GaN FET power bridges, and absolute encoders directly behind the motor stator. Thermally conductive structural epoxy provides dual-duty PCBA heat sinking and structural mounting.
Linear actuators utilized in humanoid ankles and spine assemblies require epoxy potting capable of dampening continuous axial vibrations while maintaining precise concentricity with inverted roller screws.
Replacing traditional rotor carbon fiber sleeves, high-strength structural epoxies secure segmented Neodymium-Iron-Boron (NdFeB) magnets onto rotor hubs with exceptional shear adhesion (>22 MPa) under extreme acceleration rates (>10,000 rad/s²).
Anticipating the next decade of commercial humanoid mass manufacturing through cutting-edge polymeric breakthroughs.
Future humanoid generations demand even lighter weight without sacrificing continuous torque capability. Emerging R&D at Songxi is pioneering hybrid filler systems incorporating surface-functionalized graphene nanoplatelets (GNPs) and oriented hexagonal boron nitride (h-BN).
This breakthrough yields directed, anisotropic thermal conductivity exceeding 5.0 W/m·K along the axial winding axis, funneling heat directly outward to the joint housing while maintaining superior electrical isolation (>10¹⁴ Ω·cm).
As humanoid robotics transitions to automotive-scale gigafactory manufacturing lines producing hundreds of thousands of units per year, multi-hour thermal oven curing represents an unacceptable cycle time bottleneck.
Next-gen UV-initiated dual-cure epoxies enable surface fixing in under 15 seconds followed by rapid low-temperature latent thermal curing, cutting joint manufacturing assembly times by more than 75%.
Songxi Technology is a high-tech enterprise specializing in the R&D, production, and sales of electronic adhesives. Based on silicone, polyurethane, acrylic, and epoxy systems, we provide reliable bonding, sealing, and protection solutions for power electronics, optoelectronics, new energy, automotive, and aerospace industries.
We are committed to becoming a trusted provider of functional polymer material solutions for the electronics industry. Through continuous innovation and application development, we promote the localization of high-end electronic adhesives and help intelligent devices achieve greater stability and durability.
With our deep technical background in joint motor encapsulation, thermal potting, and high-frequency EMI shielding, Songxi is empowering leading robotics OEMs to build lighter, more powerful, and exceptionally reliable humanoid robotic systems for global commercial deployment.
Delivering advanced material technologies tailored for high-performance industrial and robotic applications.
Songxi's business covers three functional areas: adhesive & sealing, potting & protection, and thermal interface materials. Our product portfolio includes PCBA fixing adhesives, UV adhesives, sealants, thermal conductive potting compounds, thermal greases, pads, two-component thermal gels, EMI shielding sealants, and reactive hot melt adhesives.
Our products serve power batteries, photovoltaic modules, drones, automotive electronics, 5G communications, and LED lighting. We provide both standard products and customized solutions for applications such as BMS conformal coating, IGBT thermal filling, and power battery structural bonding, supported by extensive technical experience and application expertise.
Led by a Ph.D. in Polymer Materials from Sichuan University, Songxi's R&D team has nearly twenty years of silicone application experience and has participated in over 100 product development projects. We maintain cooperation with research institutions including Chenguang Chemical Research Institute, Sichuan University, and Beijing Institute of Technology. Certified with ISO9001, Songxi operates a comprehensive management system covering procurement, production, inspection, and after-sales service. Our products comply with RoHS and REACH requirements, with SGS verification and UL 94 V-0 flame retardant certification, ensuring consistent quality and reliable delivery.
Comprehensive selection of conductive epoxies, structural adhesives, EMI shielding compounds, and high-dielectric potting resins for next-generation humanoid and industrial actuators.
Songxi adheres to integrity and quality throughout material selection, production, and delivery, turning reliability into a competitive advantage and earning long-term customer trust through professional service and continuous improvement across global markets.