Coupled electromagnetic-thermal modelling of 3D-printed iron core of high speed PM motor

Additive manufacturing (also known as 3D-printing) is opening up new ground for innovations in customizable, scalable and cost-efficient motor design solutions. The continuous effort to improve the efficiency and reduce the production costs of electric motors has led researchers to search for new and innovative manufacturing techniques. Such a new technique enabling construction of electric motor parts is 3D printing. The production of mechanical components by means of 3D printing, although is actually at an early stage of adoption, seems to offer important advantages. Thus, the interest of the research community in determining the quality, reliability and performance of 3D printed motor parts grows rapidly, focusing o n challenges that are related to the design and construction of high-speed motors with high efficiency and power density. This paper presents the thermal analysis of a particular 3D-printed magnetic iron material (which is commercially available) used for the design and manufacturing of the stator core of a low-power and high-speed permanent magnet synchronous motor. The findings of the simulations were confirmed experimentally.