From Technology to Field-Proven Product
EC-Profile’s proprietary electrochemical stator machining technology is not an unproven laboratory concept. It is the manufacturing foundation behind serial downhole power sections deployed across more than 50 countries worldwide, now accessible to independent motor and pump OEMs.
Reference Case: Full-Metal-Power
Commercial Power Sections & Downhole PDM Motors • Metal-to-Metal • 300°C+ (Continuous HPHT)
THE CHALLENGE
Metal-to-Metal progressive cavity power sections replace the elastomer with precisely manufactured metal rotor and stator profiles. That makes the long, internal helical stator geometry the critical manufacturing step. It has to be produced with controlled accuracy and consistent quality to achieve the required operating clearances and performance.
THE SOLUTION
EC-Profile builds on electrochemical machining expertise developed since 1996 and continued within ECM Technologies since 2003. Stator development started in 2012. The first electrochemically machined stator was demonstrated in 2013, and small-series production followed in 2017. Since then, the process has been developed continuously across different sizes and lobe configurations.
THE RESULT
In 2020, Full-Metal-Power was launched as the commercial brand for complete Metal-to-Metal power sections, with EC-Profile manufacturing the internally profiled stators for its entire range. Today, Full-Metal-Power’s products are deployed in more than 50 countries.
NOW AVAILABLE TO INDEPENDENT OEMS
The same manufacturing capability is now open to OEMs that develop their own progressive cavity motors and pumps. EC-Profile operates as a separate legal entity. Your PDM/ PCP products can be introduced as white label.
“The stator was always the limitation. We spent years solving it for our own power sections. Now we offer that capability to other manufacturers, so they can build their own Metal-to-Metal products, with their designs staying fully their own.”
Application Benchmarks Available Under Mutual NDA
Up to 6.0 m Continuous 7:8 Lobe Stator Housing
Deep downhole motor benchmark in pre-hardened AISI 4145H steel with zero tool deflection and seamless monolithic wall structure.
300°C+ Elastomer-Free Full-Metal Power Section
Supercritical geothermal pumping cavity with modeled conjugate cycloidal differential thermal expansion and complete sour gas immunity.
Uniform-Wall Evenwall Helical Stator Tube
Precision internal helix geometry enabling uniform-thickness elastomer injection, eliminating localized hysteretic heating in heavy crude lift.
High-Hardness Nitriding Steel Dosing Stator
Non-contact electrochemical profiling in aluminum-bearing 1.8550 nitriding steel with zero cutter degradation and fine technical finish.
Proprietary tool designs, client rotor coordinates, and exact manufacturing data remain protected under bilateral NDA. EC-Profile does not sell downhole tools or complete motors directly to end-users.
READY TO INTRODUCE METAL-TO-METAL POWER SECTIONS?
Connect directly with our stator manufacturing engineering team at Orionweg 55, Leeuwarden.