Prototyping and Optimization of 100,000 rpm Additively Manufactured SyR Rotors

This paper presents the characterization of a two-pole, 100,000 rpm, 1 kW synchronous reluctance motor prototype, equipped with a 3D-printed axially-laminated solid rotor produced using the bi-metallic Direct Energy Deposition additive manufacturing technology. The comparison between the initial design and the real machine is based on both FEA-computed and measured inductance maps as well as on-load tests conducted on the existing prototype. Also, this paper focuses on optimizing the rotor structure by adjusting the rotor layer thickness and positioning to minimize torque ripple and total losses, providing interesting insights valuable for designing axially laminated solid rotor structures.