High-Performance Electrical Machine Windings Enabled by Metal Additive Manufacturing
This work explores how metal additive manufacturing (AM) can unlock higher-performance electrical machine windings by enabling optimised conductor geometries, integrated cooling features, and tailored insulation systems. It addresses three key barriers to industrial adoption: systematic AM winding design, reliable electrical property characterisation, and robust insulation of complex as-built surfaces. Together, these developments support more efficient, power-dense and reliable machines needed for future electrified systems.
- AM-enabled winding design optimisation: computational tools to generate shaped conductors, full coil geometries, and integrated thermal management features.
- Electrical property characterisation: a practical resistance-based method to measure conductivity and temperature coefficient with repeatable, uncertainty-bounded results.
- Surface preparation and insulation development: post-processing and evaluation of advanced insulation systems for complex AM surfaces.
- Industrial relevance and performance impact: reduced AC losses, improved cooling pathways, and improved reliability for high power-density machine applications.
Wednesday 20 May 11:55 - 12:25 Electric Motor Forum Electric Motor Forum Stage
Manufacturing Technologies and Innovations
This work explores how metal additive manufacturing (AM) can unlock higher-performance electrical machine windings by enabling optimised conductor geometries, integrated cooling features, and tailored insulation systems. It addresses three key barriers to industrial adoption: systematic AM winding design, reliable electrical property characterisation, and robust insulation of complex as-built surfaces. Together, these developments support more efficient, power-dense and reliable machines needed for future electrified systems
Electric Motor Forum Stage Europe/London
Speakers
Senior Research Associate, University of Bristol
