Design and Optimization of Electrical Machines
Multi-disciplinary design optimization
Optimal balance between losses, weight, and cost.
Higher power density (above 25 kW/kg).
Material tradeoff and selection of best-in-class solutions.
Free shape optimization of windings at stranded level.
Unmatched efficiency for radial and axial flux machines.
Customized Lightweight Windings
Shape-Profiled Coils
Minimized high-frequency losses.
Thermal uniformity and mitigation of hotspots.
3D Printing of aluminum for highest sustainability.
Best-in-Class Electrical Insulations
3D Printed Coils for Radial and Axial Flux Machines
Wide Range of Coating Systems.
Excellent Edge Coverage.
PDIV-free insulation.
High thermal class (180-220°C).
High-end polymers for extremes.
Hairpin Windings
Quickest Prototyping
Highest Fill Factor
Lowest Weight
Maximum Cost saving
Development of Novel Concepts
Perfect Fit in any Slot Shape
Manufacturing in near-net shape without any tooling (e.g. bending, welding, etc.)
High Compactness
Repeatable Quality
High Productivity
Thermal Management
Customized Heat Exchangers
Optimized Direct Cooling Channels
Improved Contact Surface
Tight Tolerances
Coils with Zigzag-Profile Turns
End Winding Cooling
Lightweight inserts that can be integrated with cooling channels for better cooling of the end windings
Boosted Performance
Hotspot Mitigation
Internal Micro-Features
Higher Flexibility
Testing and Quality Assurance
Validated key Data
Electric Test: AC High Frequency Losses
Thermal Test at Rated Conditions
Core Loss Separation and Magnetic Material Characterization
Efficiency Map and Field-Weakening Test
Insulation Quality: Partial discharge inception voltages (PDIV Test)
Endurance test and Lifetime assessment
Contact our team for more information:
info@usp3d.be