Case Studies
Motor technology is what we do. Since 2007, ETM’s expert team has been pioneering and perfecting the long-elusive Transverse Flux Motor technology. Our breakthrough TFM technology is now proven globally, delivering millions of operating hours in a wide range of applications.
XT Paint Sprayer & ETM
15x
more torque than traditional motors
90%
lower running speeds
10x
quieter operation
50-3,300 psi
widest performance range in the industry
Graco revolutionizes airless spray performance with ETM’s Transverse Flux Motor technology
For almost 100 years, Graco has been the trusted name in fluid handling systems and equipment. As the market leader in professional painting equipment, Graco serves contractors across residential, commercial, and industrial applications worldwide. When developing the next generation of airless sprayers, Graco turned to ETM, now the electric motor division of Graco, to pioneer a motor specifically designed for the unique demands of airless spray applications.
Products used: Transverse Flux Motor (TFM) Technology
Industry: Professional Painting Equipment
The physics of the TFM design opened up possibilities we couldn’t achieve with conventional motors.
Mark Shultz
VP Global Engineering, Graco Contractor Division, Graco, Inc.
Challenge
Professional painting contractors take pride in consistently delivering the highest quality finish. This requires equipment that delivers next level performance, handles diverse applications, and operates reliably in demanding job site conditions. Traditional brushless DC motors in airless sprayers required complex multi-stage gear trains to achieve the torque needed for high-pressure paint delivery, resulting in mechanical complexity, increased noise levels, and limited pressure control precision.
“Contractors frequently operate long hours across residential neighborhoods, commercial buildings, and industrial facilities where municipal noise ordinances apply. These laws directly restrict spraying activities to defined daily timeframes, most commonly between 8:00 AM and 5:00 PM during the workweek,” said Jarrod Drexler, Graco Senior Engineer. “But the real challenge was achieving high torque at low speeds without the heat, vibration, and mechanical complexity that comes with traditional motor designs. We needed a fundamentally different approach.”
Graco sought a motor solution that could eliminate gear reduction systems, provide precise pressure control across an unprecedented range, and dramatically reduce noise—all while simplifying the overall sprayer design for easier manufacturing and field maintenance.
Solution
Built on ETM’s proprietary Transverse Flux Motor (TFM) technology, Graco integrated the Xtreme Torque Motor—the first motor ever designed specifically for airless spray applications. The XT motor delivers 15 times more torque than traditional brushless motors, enabling direct drive to the sprayer’s piston pump without any gear reduction.
“The simple design of the TFM technology was a game-changer for our development process,” said Jarrod Drexler. “We could rapidly prototype different performance configurations and quickly optimize for specific pressure ranges.”
The XT motor’s high torque and low inertia design enables Graco’s proprietary Rapid-Response™ Control system to instantly adjust motor speed to eliminate 75% of pressure fluctuations. This precision delivers the steadiest running pressure in the industry, adjustable in 10 psi increments across an unprecedented 50-3,300 psi range
Results
Industry-leading performance that transforms the contractor experience
The Graco XT Sprayer powered by ETM’s motor technology has redefined what contractors expect from professional airless equipment. The performance is unmatched allowing painters unprecedented control to deliver show-quality finishes in all situations. Operating at 90% lower speeds than traditional motors while delivering superior torque enables whisper-quiet operation—up to 10 times quieter than conventional sprayers—earning recognition as “The New Sound of Quality” on job sites.
Simplified design accelerates development and reduces complexity
ETM’s TFM technology enabled Graco to consolidate their motor portfolio from 10 different motors across mid-size sprayers down to just 5, streamlining manufacturing and inventory. The direct-drive configuration eliminates dozens of mechanical components, reducing assembly complexity and potential failure points.
Wide application versatility from a single platform
The 50-3,300 psi operating range gives contractors unprecedented flexibility to use the same sprayer across applications that previously required multiple machines. Whether spraying fine finishes with small tips or heavy coatings with large tips, the XT motor maintains stable pressure control through precise torque management and low-inertia responsiveness that prevents pressure overshooting.
Graco continues to explore additional applications for ETM’s high-torque, low-speed motor technology across their broader product portfolio, leveraging the same design advantages that transformed Graco’s XT Sprayers.
Rapid prototyping enables faster innovation cycles
The adaptable toroid design allows Graco engineers to modify coil configurations to hit different performance targets without redesigning the entire motor platform. This flexibility transforms the development timeline from months to days for new sprayer variants, enabling Graco to respond quickly to market demands and contractor feedback.
“We eliminated the cooling fan attached to the motor, replacing it with a simple computer fan that only turns on when necessary. That single change—made possible by the transverse flux motor’s efficiency—removes a major source of noise and greatly reduces the overspray contamination that comes with moving large volumes of air. The physics of the TFM design opened up possibilities we couldn’t achieve with conventional motors.”
Mark Shultz, VP Global Engineering, Graco Contractor Division, Graco, Inc.
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