INTERNALLY PROFILED METAL STATORS
“THE STATOR WAS ALWAYS THE CHALLENGE.”
The rotor is generally the more accessible component to manufacture. The long, accurate, complex internal helical profile of the stator is the manufacturing barrier that many OEMs cannot easily overcome. EC-Profile exists to close that gap with continuous lengths up to 6.0 meters (20 ft).
TWO CUSTOMER ROUTES TO SUIT YOUR SUPPLY CHAIN
Whether you already possess finished CAD coordinates or require cycloidal geometry design from scratch, we adapt to your engineering workflow.
BUILD-TO-PRINT STATOR MANUFACTURING
CUSTOMER OWNS ROTOR & STATOR GEOMETRY
You supply the stator drawing, lobe profile coordinates, and dimensional envelope. EC-Profile manufactures the complex internal profile to your exact tolerances, while you maintain full control of your design and rotor supply chain.
- Complete customer IP ownership and confidentiality under mutual NDA upon request
- Lengths up to 6,000 mm (20 ft) in a single continuous piece
- Standard high-strength alloys: 4140, 4145, 4330, and 1.8550
- Internal contour runout and wall thickness within ±0.08 mm
DESIGN + MANUFACTURE COLLABORATION
NEW MTM OR HIGH-EFFICIENCY PUMP/MOTOR DEVELOPMENT
Customer wants to develop a new Metal-to-Metal (MtM) motor or high-performance positive displacement pump. We support cycloidal kinematics, lobe ratio optimization, and clearance calculation, while you manufacture your own rotor.
- Matched rotor and stator coordinate generation
- Lowers customer recurring component cost vs. buying full power-sections
- Rapid prototype profiling for bench and dynamometer testing
- Zero mechanical stress introduced by ECM machining process
EVENWALL & MULTI-LOBE CAVITY ARCHITECTURES
From 1:2 (monolobe) to multi-lobe configurations (including 3:4, 4:5, 5:6, 6:7, 7:8) across Evenwall elastomer housings to solid Metal-to-Metal (MtM) profiles, our non-contact electrochemical process profiles intricate helical trajectories without residual mechanical stress.
EVENWALL STATOR TUBES
Internally profiled metal tube geometry matches the contour of the rotor lobes, ensuring constant elastomer thickness throughout the cavity. Reduces thermal hysteresis, heat build-up, and swelling failure.
PDM & PCP CAVITIES
Helical multi-pitch geometries engineered for well intervention and directional drilling positive displacement motor (PDM) and progressive cavity artificial lift pumps (PCP), accommodating high torque transfer and viscous fluids.
FULL-METAL PROFILES
Precision solid steel internal profiles capable of metal-to-metal sealing with conjugate rotors. Field-tested up to 330°C (laboratory tested up to 500°C depending on material) for extreme geothermal and chemical environments.
MANUFACTURING CAPABILITY SPECIFICATIONS
| Parameter | Capability Envelope | Engineering Advantage |
|---|---|---|
| Continuous Length | Up to 6,000 mm (20 ft) | Single-piece continuous internal helical profile without segment welds. |
| Outside Diameter (OD) | 1.0″ to 8.0″ (25 mm – 203 mm) | Covers small industrial dosing pumps to large downhole power sections. |
| Profile Runout Tolerance | ±0.08 mm (±0.003″) | Repeatability within 10–20 µm along entire continuous length. |
| Wall Thickness Uniformity | ±0.08 mm (±0.003″) | Crucial for Evenwall elastomer adhesion and uniform thermal expansion. |
| Standard Steel Alloys | 4140, 4145, 4330, 1.8550 | High-fatigue, heat-treated alloy steels machined without Heat-Affected Zone. Specialized surface treatments available for sour H2S environments. Alternative alloys to be discussed. |
| Tool Wear & Cutting Force | 0.00 N (Non-contact) | Electrochemical removal eliminates mechanical cutter wear and microcracks. |
FREQUENTLY ASKED QUESTIONS
HAVE A STATOR DRAWING OR CAD MODEL TO EVALUATE?
Submit basic dimensions or drawings via our secure RFQ portal. Protected under mutual NDA upon request.