Air & Foil Bearing Development | SADAP Germany
SADAP Background

Aerodynamic Bearing Solutions

Precision for the Highest Demands

Air & Foil Bearing Development | SADAP Germany
10+

Years of expertise in development AND design of aerodynamic air and foil bearings – from theory to series production

Development of Air and Foil Bearings

Where science meets manufacturing practice – precisely tailored solutions for real-world applications

Why aerodynamic bearings cannot be catalog solutions

Aerodynamic bearings cannot be standardized – each application requires a precisely tailored design. The demands of turbochargers, dental compressors, or microturbines differ fundamentally. Based on multiphysical simulations capturing geometry, manufacturing tolerances, and real operating conditions, validated, efficient, and durable bearing solutions are developed.

Comprehensive Development Framework

We analyze every critical parameter – from fundamental physics to application-specific challenges – ensuring optimal bearing performance across all operating conditions

1

Operational & Environmental Parameters

Gas Media & Pressure Analysis

Foundation of load capacity
  • Air: 1-10 bar standard applications
  • Hydrogen: up to 50 bar for fuel cells
  • Helium: Cryogenic conditions
  • Guaranteed minimum load at all pressures

Thermal Management

Critical for high-speed operation
  • Passive cooling with optimized fins
  • Active cooling channels design
  • Lambda-based strategies to 400°C
  • Thermal network modeling

Speed & Dynamic Range

From startup to peak performance
  • Operating range: 10k-200k RPM
  • Critical speed mapping
  • Transient response analysis
  • Start-stop cycle optimization
2

Mechanical Design & Materials

Coating Technology

Durability enhancement
  • Validated for >100,000 cycles
  • DLC & polymer-based systems
  • Tribologically optimized surfaces
  • Wear prediction from field data

Vibration & Stability Control

Critical for reliability
  • Self-excited vibration damping
  • External excitation isolation
  • Whirl instability prevention
  • Stability maps for all operating points

Manufacturing Integration

Series production ready
  • Tolerance stack-up analysis
  • Cost-optimized geometries
  • Assembly-friendly design
  • Quality control integration
3

Development Process & Validation

Requirements & Feasibility

Phase 1: Analysis

Detailed capture of operating conditions, load profiles, environmental factors. Feasibility assessment with risk analysis and preliminary design concepts.

Design & Simulation

Phase 2: Optimization

AI-powered multiphysics analysis, coupled thermal-structural simulations, rotordynamic optimization, and manufacturing constraint integration.

Prototype & Testing

Phase 3: Validation

Manufacturing with optimized coatings, performance validation under real conditions, durability testing, and comprehensive documentation.

Series Transfer

Phase 4: Production

Quality assurance concepts, supplier qualification, first article inspection, production ramp-up support with continuous improvement.

4

Advanced Simulation & Analysis

Multiphysics Integration

Coupled analysis approach
  • Fluid-structure interaction (FSI)
  • Thermal-mechanical coupling
  • Electromagnetic effects analysis
  • Real material models from field data

AI-Powered Optimization

Machine learning enhanced
  • Trained on industrial data
  • Cost-performance optimization
  • Failure prediction algorithms
  • Continuous learning from field feedback

Validation Accuracy

Industry-proven precision
  • ISO/DIN standard compliance
  • Correlation with test data >95%
  • Manufacturing partner validation
  • Documented success metrics
5

Application-Specific Challenges

⚠️ Critical Example: Unbalanced Magnetic Pull (UMP) in Electric Motors

The Hidden Danger in Motor-Integrated Bearings:

When aerodynamic bearings operate within electric motors, magnetic forces from the motor can destabilize the rotor. This Unbalanced Magnetic Pull (UMP) creates a positive feedback loop: small eccentricities generate magnetic forces that pull the rotor further off-center, potentially causing catastrophic bearing failure.

At SADAP, we master this challenge through electromagnetic-aerodynamic coupled analysis, ensuring stable operation even in high-power motor applications.

Our UMP Solutions:

  • Electromagnetic force mapping
  • Critical eccentricity analysis
  • Optimized bearing stiffness design
  • Various damping strategies
Click to explore interactive UMP visualization →

Understanding Unbalanced Magnetic Pull (UMP)

Critical Challenge in Motor-Integrated Aerodynamic Bearings

Why UMP Matters for Your Application

When aerodynamic bearings are integrated into electric motors, the electromagnetic fields create destabilizing forces that conventional bearing design often overlooks. These forces can rapidly escalate from manageable to catastrophic.

  • Linear Regime (Small Eccentricity): UMP force grows proportionally with displacement (F∝e). The bearing can typically compensate with proper stiffness design.
  • Transition Zone: Mixed behavior where both linear and quadratic terms contribute. Critical design zone requiring careful analysis.
  • Quadratic Regime (Large Eccentricity): Force grows with the square of displacement (F∝e²). Rapid, uncontrollable force escalation leading to bearing failure.
  • Weight Effect: Heavier rotors cause static deflection, pushing the system closer to the dangerous quadratic regime even at rest.

SADAP's Advantage: Our advanced simulation tools capture these electromagnetic-aerodynamic interactions, allowing us to design bearings that maintain stability across all operating conditions. We optimize bearing stiffness, damping, and geometry to counteract UMP effects before they become critical.

Interactive UMP Simulator

Explore how magnetic forces interact with bearing dynamics in real-time

Force Analysis

F_UMP = K₁·e + K₂·e²
Total UMP Force
0 N
Eccentricity Ratio
0.00

Rotor Position

System Parameters

SADAP Service Packages

Tailored solutions for your requirements: From scientific analysis to series-ready production – our service packages combine theoretical excellence with practical feasibility.

Standard Package recommended for:

  • Small and Medium Enterprises (SMEs)

    Ideal for initial developments, feasibility studies, and quick prototype solutions

    e.g.: Mechanical engineering SMEs, development service providers, start-ups, research institutes

Premium Package recommended for:

  • Industrial Companies & OEMs

    Optimized for series production, critical applications, and customer-specific developments

    e.g.: Turbomachinery manufacturers, automotive suppliers, medical technology, aerospace

Standard Package

Proven solutions with quick availability – Science for practice

Prototype Scope 4-8 complete bearing sets from proven portfolio

Standardized Prototype Manufacturing

  • 2 radial bearings + 2 thrust bearings per set
  • Selection from proven standard geometries
  • Quick availability (from 2-3 weeks)
  • Cost-effective manufacturing with partners
  • Adaptation to your shaft diameters
Bearing Design Adaptation of proven designs to your application

Field-Proven Fundamentals

  • Selection from catalog of successful designs
  • 2D pressure field analysis with practical factors
  • Load capacity according to industry standards
  • Manufacturing-compliant tolerances
Technology & Support Solid analysis with practical consultation
  • Validated standard models
  • Installation recommendations
  • Operating instructions
  • 30 days technical support

Project Timeline

4-8 weeks Total project duration
from 2-3 weeks Prototype manufacturing
Catalog selection From proven designs

Premium Package

Tailor-made development for your series – From science to economic viability

Exclusive Prototype Development Customer-specific design for your application

Optimized for Series Production

  • Individual bearing configuration
  • Design for minimal production costs
  • Adaptation to your manufacturing processes
  • Material optimization for large series
  • Assembly-friendly construction
  • Supplier qualification included
Advanced Bearing Design optimized for maximum efficiency at minimum cost
  • Cost optimization per performance unit
  • Robustness analysis for series variation
  • Lifetime prediction under real conditions
  • Patentable innovations
Series Transfer Complete package up to production
  • Manufacturing drawings & specifications
  • Tool concepts for your production
  • Quality assurance concept
  • Supplier audit & approval
  • First article inspection & PPAP
  • Production ramp-up support
Economic Optimization ROI-focused development
  • TCO analysis (Total Cost of Ownership)
  • Scaling concepts for different quantities
  • Second-source strategies
  • Continuous cost reduction

Project Timeline

12-16 weeks Development to series
Cost optimization For your target quantities
Pilot series With your manufacturing partners
6 months Production support

Detailed Performance Comparison – Science and Practice United

Performance Features Standard Package Premium Package
Prototype Scope 4-8 standard bearing sets Unlimited, customer-specific
Manufacturing Optimization Standard processes Cost-optimized for your production
Design Approach Proven catalog solutions Exclusive for your application
Series Support Installation instructions Complete production support
Cost Analysis Unit cost prototype TCO & scaling concepts
Supplier Integration Recommendations Qualification & audit
Tool Concepts – For your manufacturing equipment
Quality Assurance Standard test protocol QA concept & PPAP
Documentation Technical report Complete series documentation
Support 30 days 6 months production ramp-up

Industry Connections – Where Our Bearings Are in Use

Automotive Industry

Turbochargers, e-compressors, fuel cell air supply – series-proven solutions for millions of vehicles

Medical Technology

High-speed spindles for dental handpieces and surgical instruments – certified and in clinical use

Energy Technology

Microturbines, expanders, compressors – reliable in 24/7 operation under extreme conditions

Aerospace

Auxiliary Power Units (APU), Environmental Control Systems (ECS), cabin air blowers – highest reliability for critical aerospace applications

Adaptive Solutions

At SADAP, we understand that every company has different needs. While our custom development services offer you a turnkey solution, technically savvy teams can also use our revolutionary RoLaSIM software to independently develop and optimize aerodynamic bearings.

Discover RoLaSIM – our professional simulation software for the independent design of rotor dynamics and aerodynamic bearings. With AI-powered algorithms, validated accuracy, and intuitive operation – the same technology our experts use for your projects.

Your Customized Bearing Solution Starts Here

Benefit from over 10 years of expertise in air and foil bearing development. Whether you need a standard package for initial prototypes or a premium package for series development - we offer the optimal solution for your specific requirements. Let's work together to make your project successful.