Evaluation of 3D-Printed Magnetic Materials For Additively-Manufactured Electrical Machines

Nowadays, going beyond the 2D conventionally laminated structures is essential for improving the functionality of an electrical machine during the design process. Additive manufacturing (AM) offers unmatched 3D freedom for processing metal-based materials optimized for weight and cost effectiveness. Using this technology, new families of electrical machines can be manufactured which are difficult to be built using conventional methods. This paper is mainly targeting printing and testing of ferromagnetic material. Using different AM techniques, different parts are built using the silicon steel (Fe-3 wt%Si) powder. The magnetic properties of these parts are measured and compared. Accordingly, a proper AM technology is identified as a promising method to manufacture magnetic materials. Additionally, quasi-static measurements are performed at low frequencies to compare the hysteresis losses of the 3D printed samples with those in conventional Fe-Si laminations. Results shows that good magnetic properties can be obtained from the 3D printed samples. Finally, the potential of 3D multi-material printing is highlighted for electrical machines.