Study on Stator Core Design of Axial Flux Permanent Magnet Motor for Urban Air Mobility Considering Manufacturability

This paper presents the stator core design of a 100 kW-class axial flux permanent magnet motor for a five-seat urban air mobility platform. Conventional electrical steel shows excellent magnetic properties, but its laminated structure limits the realization of complex geometries. To address this, a stator core structure combining soft magnetic composite material, which provides high design flexibility, with electrical steel is proposed. In addition, a final model applies grain-oriented electrical steel with magnetic anisotropy to the core insert for enhanced performance. The proposed structure achieves stronger flux concentration and lower copper loss at rated torque than conventional models, thereby improving torque, output power, and efficiency. Finite element analysis is employed to quantitatively evaluate the electromagnetic performance of each model, verifying that the proposed stator design is an effective solution for high-performance and efficient urban air mobility motors.