Metal 3D printing of synchronous reluctance motor

Additive Manufacturing in Construction of Electrical Machines – A Review

“…6. Examples magnetic cores fabricated using AM, a) rotor prototype for a surface mounted PM machine -University of Nottingham [19], b) rotor prototype for a switched reluctance motor -VVT Technical Research Centre of Finland Ltd. [20] c) stator and rotor hardware for an induction machine -Oak Ridge National Laboratory [21], CAD and hardware of rotor and stator core packs for a line start synchronous reluctance machine -National Cheng Tung University [22] design, a number of material performance measures need to be accounted for. These include electromagnetic properties like magnetic saturation, magnetic permeability and specific power loss, and mechanical properties including yield strength, thermal expansion and resilience to thermal cycling.…”

“…The next two examples presented in Figs. 6c) and 6d) illustrate parts of two different machine topologies: an induction machine with a cast aluminium squirrel cage [21] and a line start synchronous reluctance machine [22]. In both cases the research focus was placed on AM of the machine parts, with limited information on the machine performance gains achieved by employing AM.…”

“…All the above examples of using AM in construction of the soft magnetic parts show different levels of maturity. They start with the detailed research on metallurgical aspects of material processing when using AM [19] and finish with design exercises showcasing capabilities and potential benefits of AM in application to electrical machines [20]- [22]. There is no evidence as yet of a complete machine assembly, with parts of the magnetic circuit being fabricated using AM, and experimentally derived performance measures of such a machine build.…”

Additive Manufacturing and Testing of a Soft Magnetic Rotor for a Switched Reluctance Motor

“…smart material utilization) [3]. AM technologies have only recently been utilised in the development of parts for electrical machines (EMs) [4][5][6], which can be attributed to the lack of AM processable materials with the necessary properties for such applications [7]. Among AM build strategies, the laser powder bed fusion (LPBF) method is the most suitable for producing highly detailed metallic parts [3] and it has been extensively applied in manufacturing structural materials.…”

“…In literature, several examples of EM components fabricated via LPBF process can be found, although comprehensive analyses, accounting for the experimental comparison between 3D printed and conventionally manufactured EMs, are difficult to find. The viability of the LPBF technology is demonstrated in [5], which features the rotor structure of a synchronous reluctance machine. Details regarding the feedstock metallic powder are given along with the magnetization curve (i.e.…”