Comprehensive Overview of Using Additive Manufacturing for Multiphysics Performance Improvement of Electric Machines

Additive manufacturing (AM) has revolutionized the design and construction of electrical machines (EMs), allowing for the creation of customized structures, complicated geometries, and unique material compositions that are not possible with traditional manufacturing processes. By reducing raw material consumption, integrating advanced thermal optimization strategies, and enhancing conventional power density and efficiency limits, AM enables the development of high-performance EMs, thereby contributing to sustainable and energy-efficient solutions. This paper presents a detailed examination of AM concepts aimed at improving the multiphysics performance of EMs. Recent improvements in various topologies have also been discussed, with a focus on weight reduction, magnetic issue mitigation, magnetic field intensity augmentation, hot-spot reduction, and overall thermal management. These advancements facilitate the design of the next generation of high-performance and sustainable EMs.