Tau :Powering the Shift to E-Mobility

Tau is at the forefront of a transformative shift in the automotive industry, driven by the increasing demand for compact and powerful motors. The company specializes in the production of magnet wire, which forms a fundamental component of any electrical machine, such as electric motors, transformers, and generators. With its focus on efficient and sustainable winding wires, Tau plays a vital role in developing the electric motors used in EVs.

Tau leverages an ecologically responsible manufacturing process for magnetic wires brought through thorough research. The DryCycle process, invented by Francesco Piero and Filippo, enables Tau to sustainably produce high-performance magnet wires. Compared to the traditional method used for a century, its approach omits solvent-based coating.

“Our DryCycle process efficiently coats copper wire with insulating polymers to create a sustainable, cost-effective product. While many operators know what constitutes the best wire, our technologies make it possible to produce it,” says Filippo Veglia, founder and sales director of Tau.

Its unique technique overcomes one of the main drawbacks of using solvents in polymer production. Along with exacerbating pollution, increasing production costs, and adding compliance difficulties, using solvents limits the options for using high-performing polymers that don’t melt in solvents.

The use of techno-polymers, notably, offers an economic advantage by reducing costs in motor production. Although the insulating polymer is more expensive and the wire costs slightly more than traditional wires, depending on geometry and other factors, the overall cost of the motor is reduced. These motors are more compact and require less copper, electrical steel, and permanent magnet components, delivering increased efficiency and power density.

Tau’s wires offer high insulation and a low carbon footprint, making it an attractive option, particularly for cost-effective solutions that meet environmental regulations, such as in the automotive industry. Its full recyclability further adds to its appeal, as components that cannot be recycled are subject to taxes and fees for disposal. Magnetic wires created using DryCycle also exhibit greater temperature endurance. They are ready for 800 volts and above, making them suitable for various electric motors, cars, buses, trucks, and aircraft.

The wire coating machines developed by Tau are highly efficient and compact. In contrast to traditional technology that requires large vertical machines, its machines are 7 to 9 meters long and do not require an oven or curing process. Tau has 100 percent ownership of the manufacturing machines. These machines are constructed locally in Italy with adherence to European standards of excellence.

Currently, Tau is weighing its options to provide convenience to its clients worldwide. Although manufacturing in Europe benefits European clients, its offshore clients require a localised manufacturing unit. In the future, Tau aims to tackle various challenges in the current business environment arising from production in different regions, including high costs and political risks.

Tau’s cutting-edge technology has received significant market recognition, with interest expressed by seven of the top ten automotive manufacturers and associated tier-one firms. This suggests a strong level of value and quality in its products.

Moving forward, Tau's innovative technology has the potential to revolutionize the electric vehicle industry and contribute significantly to a sustainable and cleaner future.