Powertrain & Drivetrain Technology

Borman's engineering teams specialize in the design and optimization of highly integrated e-axle systems that consolidate electric traction motors, multi-speed transmissions, power electronics, and thermal management components into compact, unified assemblies. This specialty addresses the critical industry transition from distributed powertrain layouts inherited from internal combustion architectures toward purpose-built electric propulsion systems. Engineers at Borman develop advanced packaging solutions that maximize power density while minimizing mass, focusing on the thermal integration challenges inherent in combining high-power electrical components with precision mechanical systems. The facility's prototyping capabilities enable rapid fabrication of housing structures with internal cooling galleries, electromagnetic shielding features, and structural reinforcements that would be impractical to produce through conventional manufacturing methods. Validation testing encompasses efficiency mapping across full operating envelopes, thermal cycling durability, and electromagnetic compatibility verification to ensure these integrated systems meet stringent automotive reliability standards.

Recognizing that single-speed reduction drives impose significant compromises on electric vehicle efficiency and performance, Borman maintains dedicated expertise in the development of multi-speed transmissions specifically optimized for electrified powertrains. This specialty encompasses the design of compact, high-efficiency gear trains capable of handling the unique torque characteristics of electric motors, including instantaneous peak torque delivery and sustained high-speed operation. Engineers utilize advanced simulation tools to optimize gear tooth profiles, bearing arrangements, and lubrication systems for minimal mechanical losses and NVH characteristics. The facility's dynamometer test cells enable comprehensive evaluation of shifting dynamics, synchronization behavior, and efficiency across multiple gear ratios under representative load conditions. Borman's prototyping capabilities support the fabrication of transmission housings with optimized stiffness characteristics and the integration of advanced actuation systems for seamless ratio changes that extend vehicle range while maintaining spirited acceleration performance.

As energy storage technology advances toward solid-state chemistries promising enhanced energy density and safety characteristics, Borman has established specialized capabilities for integrating these next-generation batteries into complete powertrain architectures. This specialty focuses on the unique thermal management challenges presented by solid-state systems, which require precise temperature control across narrower operating windows than conventional lithium-ion technologies. Engineers develop integrated thermal management solutions that leverage the traction battery as a thermal buffer while maintaining optimal operating temperatures for power electronics, electric motors, and cabin climate systems. The facility's environmental test chambers enable accelerated validation of battery thermal behavior under extreme conditions, while high-fidelity simulation platforms model heat generation, dissipation, and distribution throughout integrated vehicle thermal systems. Borman's prototyping capabilities support the fabrication of custom cooling plates, phase-change material enclosures, and innovative heat exchanger geometries that optimize thermal performance while minimizing system mass and complexity.

Borman has pioneered the implementation of comprehensive digital twin methodologies that create high-fidelity virtual representations of physical powertrain systems throughout the development lifecycle. This specialty integrates multi-physics simulation platforms with real-time test data to create predictive models that accurately represent mechanical, thermal, electrical, and control system behaviors. Engineers utilize these digital twins to conduct thousands of virtual design iterations, optimizing component geometries, material selections, and control parameters before committing to physical prototype fabrication. The facility's hardware-in-the-loop systems enable virtual powertrains to interact with real control units, validating software functionality and calibration strategies prior to vehicle integration. As physical prototypes undergo testing, sensor data continuously refines the digital twin models, improving predictive accuracy and enabling reliable extrapolation of component life, maintenance intervals, and performance degradation under various operating scenarios.

The facility maintains specialized expertise in the development of next-generation electric motor topologies, with particular emphasis on axial flux configurations and advanced winding techniques that deliver exceptional power density for automotive applications. This specialty addresses the critical industry need for compact, lightweight traction motors capable of delivering sustained high performance while maintaining efficiency across broad operating ranges. Engineers at Borman utilize electromagnetic simulation tools to optimize rotor and stator geometries, magnet arrangements, and cooling strategies for specific vehicle applications ranging from high-efficiency commuter platforms to high-performance drivetrains. The facility's additive manufacturing capabilities enable the fabrication of complex motor housings with integrated cooling channels and structural features that maximize thermal performance while minimizing mass. Comprehensive dynamometer testing validates electromagnetic performance, thermal limits, and mechanical durability, while NVH analysis ensures that high-power-density motor designs operate with minimal acoustic intrusion into the vehicle cabin.