DESIGN FOR ADDITIVE MANUFACTURING (DFAM): ADDITIVE MANUFACTURED ELECTRIC MOTOR
THE CHALLENGE Additive manufacturing (AM) has been identified as an enabling manufacturing technology to produce power-dense electric motors in a repeatable and short lead time. Whilst additive manufacturing isn’t new, its application for end-use parts and tooling has become more prevalent only in recent years, and is demonstrating its potential to change the way that products are designed and manufactured. In academia, there are a growing number of research papers that highlight the benefits associated with an additive manufactured motor, however there are limited examples of AM in commercially developed products. The MTC’s technology experts initiated a project that considered the wider implications of additive manufacturing for electric motors. The aim was to provide recommendations, based on existing limitations, for creating the next generation of electric machines.
MTC’S SOLUTION With support from the National Centre of Additive Manufacturing (NCAM) and the MTC’s Electrification Steering Committee, the project team were able to identify the key challenges being faced by conventionally manufactured motors. Technology Readiness Level (TRL) and Manufacturing Readiness Level (MRL) assessments were conducted of additive manufacturing for key motor components. These assessments were combined with learnings from past projects and an analysis of present manufacturing techniques for each component. In doing so, the MTC was able to identify the current constraints and how, by, applying AM, these limitations may be resolved. To demonstrate the potential benefits of leveraging the capabilities of AM, the cooling method of a commercial motor was reassessed, as a result of several iterations of a liquid-cooled motor casing.
The development of electric motors has not seen this level of focus for nearly 100 years despite being high on the priority list for many industry sectors that are seeking significant improvements in cost, quality, reliability and performance, in both gravimetric and volumetric terms. Systems engineering and integration – doing more with key components and materials - are key to achieving this and so additive manufacturing is a key enabler for developing complex features and forms, essential to improving the functionality and performance of electric motors. Steve Nesbitt Chief Technologist, MTC
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