Multi-Material Additive Manufacturing for Electrical Machines with increased performance (AM4EM) (AM4EM)

AM4EM will investigate the use of additive manufactured (AM) parts into electrical machines (EM). In particular, we aim at additively manufactured parts that are in the electromagnetic path of the machine, like the windings or elements of the stator/rotor core. In order to do so, there is a need for additive manufacturing processes that are able to print multi-materials (MM). Multimaterials means that we can combine the following materials in complex geometries: electrically conductive materials for guiding the current, magnetically conductive materials for guiding the magnetic flux and electrically isolating materials. AM4EM will especially focus on combining two materials during printing: electrically conductive combined with an insulator, and also magnetically conductive combined with an insulator. Two similar AM processes, being filament-based printing and robocasting, will be investigated, from the feedstock over the actual printing process to the post-processing (debinding & sintering). At first, we will realise and test basic structures to gradually improve the quality of the printed materials (e.g. the electric conductivity, the magnetic properties, density, … ). Then, we will work out new concepts for electrical machine parts that require more complex geometries. They will be evaluated at TRL4. The new EM concepts will on the one hand include the potential and limitations of the MM-AM process in terms of e.g. geometry and material properties. On the other hand, the MM-AM will be developed in view of realising structures for EM that cannot be produced using traditional manufacturing techniques. AM4EM will deliver innovative MM-AM processes that can be used for e.g. sensors, radars, actuators and electrical machines. For the latter application, AM4EM targets an increase in energy efficiency by 5%point (compared to small induction machines) and an increase in power density by 40%.