Project: Ultralight 3D Printed Electrical Machine Windings Featuring Scalability and High Performance (USP 3D)

2024-07-01 – 2025-12-31

Abstract

Electrical machines are crucial in numerous sectors, from transportation to manufacturing. The traditional approach to manufacture electrical machine windings, customized for specific requirements, has been marked by high tooling costs, limited scalability, and environmental concerns. Our project introduces a groundbreaking approach, using additive manufacturing to produce Ultralight 3D Printed Electrical Machine Windings. Focusing on 3D printed aluminium windings instead of conventional windings in copper, we aim to provide solutions that are not only sustainable but also high-performing. By optimizing design, material selection, and thermal management, we have achieved significant reductions in weight and losses, while also making these technologies accessible to a wide range of industries. Our project represents a leap forward in electrical machine design, demonstrating the potential for sustainable, lightweight electrical machines, all made possible through additive manufacturing.