AM4EM aims at integrating additively manufactured (AM) parts in the electromagnetic path of a machine: windings or elements of the stator/rotor core. To do so, there is a need for AM processes that are able to print multi-materials (MM). It involves combining 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 material sets during printing: electrically conductive combined with an insulator, and magnetically conductive combined with an insulator. Two similar AM processes – filament-based printing and robocasting – will be investigated, from the feedstock over the actual printing process to the post-processing (debinding & sintering). 

The main objective is to increase the power density of electric machines by 40% and the energy efficiency by 5%point by developing and leveraging on multi-material additive manufacturing (MM-AM). More particularly the project has set three subobjectives:

Objective #1

To develop, manufacture and validate innovative parts for EM for two concepts leveraging on MM-AM: 

Novel winding geometries for electrical machines based on Cu as conducting material and ceramic as electrical insulation material. 

Innovative stator and rotor core based, consisting of sheets isolated by a thin ceramic insulator. 

Objective # 2

Develop MM-AM processes for high quality electrically conductive metals, magnetically conductive metals & ceramic insulators and their combinations, based on 3D micro-extrusion of powder filled paste and filaments with at least 40 vol% powder loading, and subsequent densification by powder metallurgical processing. 

Objective # 3

Develop a tool chain to obtain AM parts of electric machines with accurate geometry, and required electromagnetic functionality.

The goal of the project is to move from TRL 2 to 4.

To tackle the challenges that have been identified in the scope of the project, the project involves all key research groups in Flanders active in the field, i.e., the Ghent University (UGent), KU Leuven (KUL) and VITO, with long tradition and complementary expertise along the entire AM4EM process chain.

The project is guided by an Industrial Advisory Board (IAB) involving 14 main ecosystem actors. The IAB composition covers all relevant parts of the value chain(s). These companies are active in diverse sectors ensuring non-competitive and open interactions.