Additive Manufacturing of Coated Windings for Electric Machines
Additive Manufacturing (AM) is revolutionizing the production of electric machine components, offering unmatched design freedom and material efficiency. Among its transformative applications is the development of coated windings, which enhance durability, thermal management, and electrical performance. Coated windings produced via AM enable superior insulation properties under extreme electrothermal stresses, extending the operational lifespan of electric machines.
Additionally, AM facilitates the integration of innovative thermal management solutions, such as embedding cooling channels within windings, to efficiently dissipate heat and improve overall machine performance. This approach addresses key challenges in high-power density applications, where effective thermal regulation is critical.
Material engineering also plays a pivotal role in the evolution of winding, particularly in the shift from traditional copper windings to lightweight aluminium alternatives. Aluminium windings not only significantly reduce the weight of electric machines but also contribute to sustainability goals by reducing resource dependency and improving recyclability. Through advanced design and coating techniques, these aluminium windings deliver comparable performance to copper-based systems without compromising electrical efficiency or reliability
Further information and related publications can be found here: Research Explorer - Ultralight 3D-Printed Electrical Machine Windings Featuring Scalability and High Performance