Additive Drives

Applications

Whether it’s versatile single coils or complex hairpin windings, 3D printing enables unprecedented production speeds and performance increases of up to 45%.

Application 1:

Single Coil

 

The 3D printing of single coils offers great flexibility, permitting the design of single coils for any conceivable type of electric motor geometry.
The manufacturing process focuses on series production and guarantees consistent high quality, low unit costs, and short lead times.

Take a look at how a single coil has been applied in our racing motor and pedelec motor use cases.

Unlimited design freedom (with reference to geometry)

Optimally configured windings for electromagnetic and thermal properties

Maximum copper fill factor

Includes all types of electric motors (radial flux, axial flux, transverse flux)

Shorter winding head

Scalable production quantity

Faster manufacturing process

Customizable connection geometry

Application 2:

Hairpin Winding

  Hairpin windings are gaining ground in the automotive industry. Conventional manufacturing requires much longer lead times; wire procurement and the need to use bending and welding tools can prolong the development process by many months. The 3D printing process addresses this problem: test samples can be produced in a matter of weeks. Below you can view how the hairpin winding has been applied in our Prototyping E-Traction Motor Use Case.

Print-as-it-is: geometric design and material parameters as in conventional manufacturing (a prerequisite for meaningful prototyping)

3D printing of the winding in a matter of days

Shorter winding head

Scalable production quantity

Faster manufacturing process

Additive Drives Use Cases:

Single Coil in Racing Motor Use Case »

Hairpin Winding in E-Traction Motor Use Case »

Single Coil in Pedelec Motor
Use Case »

Is that it? No, there’s more to come – we’ve already started developing other applications and will gladly talk to you about what we’re doing.