Fully Additively Manufactured Multilayer Stator for Radial Flux Electric Motors

Abstract The development of hybrid-process multimaterial additive manufacturing, with conductive nanoparticle inks and electrically insulating composites, enables the design of novel electromechanical actuators. In this work, we present the design, fabrication, and characterization of a novel fully additively manufactured cylindrical three-phase radial flux stator for an electric motor. This stator is manufactured using a unique four-axis (three linear, one rotary) 3D printer. While prior work has focused on additively manufacturing planar axial motors, the stator in this work is printed on a rotating axis. This enables the creation of a radial stator with nine slots, each consisting of five layers of direct ink write silver nanoparticle ink coils encased in fused filament fabricated nylon-fiberglass insulation. After this rotary electric motor is assembled, the performance and dynamics of the motor are characterized, demonstrating 0.51Nmm/A peak torque, 0.67 Hz switching bandwidth, and continuous operation at up to 150∘C for a 20.7 W input. To demonstrate a realistic application, this 3D-printed motor is used to drill through foam. Printing the motor with the rotary axis not only enables more complex designs but also enables the manufacturing of previously unprintable 3D geometries for embedded high-power electric machines.