What is Magnetic Saturation in Motors?

Featuring Matteo Leandro, Design Engineer at Alva Industries

Saturation is a common challenge in motor design - but what is it exactly, and how can it be avoided?

In this second episode of Tech Torqs, Matteo from Alva explains what magnetic saturation is and how it affects torque generation and performance. Using a simple sponge analogy, he describes how magnetic materials like the iron core can only handle so much before reaching their limit.

Once saturation is reached, increasing current no longer produces more torque - efficiency drops, and motor performance suffers.

To avoid this, designers must carefully size and optimize the motor core. In traditional slotted motors, this often requires trade-offs between weight and torque. But in Alva’s SlimTorq™ slotless motors, our wide air gap and simplified magnetic paths reduce saturation effects, enabling:

• High transient torque
• A linear torque constant
• Stable performance under heavy loads

If you have a question about motors or motion systems, share it in the comments on our LinkedIn post or send it to us directly - we might feature it in the next Tech Torqs episode.