Anodised aluminium foil windings for sustainable YASA axial flux machines

This work proposes a novel design for a yokeless and segmented armature axial flux machine. New construction techniques are introduced to eliminate wet processes that are typically used for stator manufacturing. Anodised aluminium foil is used to construct the stator coils along with a new technique to form the electrical connections. The motor is optimized for high-speed operation up to 2 kW at 20 000 rpm using analytical and finite element models. The feasibility of the machine and the effectiveness of aluminium foil for high-frequency signals are verified using finite element simulations. Lastly, a prototype of the axial flux motor is designed and manufactured. Some initial tests are performed to validate the design.