Development and prototyping
Fastest prototyping in the world
Electric motors are the drives of the future. We support our partners in the development of new electric motors from the initial idea through electromagnetic and thermal simulation, design and production to the testing and industrialisation of their concepts.
Together we are developing the machines of tomorrow.
From the initial idea to the finished motor in 4 weeks!
Additive Drives offers the world’s fastest prototyping for electric motors and their components. By using innovative 3D printing, prototyping and small series can be realized without expensive tooling costs and in the shortest possible time.
Design
Production using innovative 3D printing enables completely new designs for electric motors. More power in the same installation space, improved thermals and higher efficiencies mean a new generation of motors close to the physical limit!
Our engineers work with various tools, including JMAG and Motor CAD for electromagnetic and thermal calculations, as well as Ansys Workbench and OptiSlang for the design and efficient comparison of variants in the optimization phase. In this way, issues such as cooling optimization or NVH can already be taken into account in the design phase.
Technology
Thanks to innovative production and patented technologies, we can manufacture not only individual components but also entire engines for our partners within just a few weeks. – Without complex tooling!
The best way to cool: Reduce losses
There are many ways to cool electric motors, from air cooling and water cooling to direct oil cooling. However, the most effective way of cooling is always to reduce losses!
Depending on the application and frequency range, different conductor structures and technologies are used: classic hairpin windings with optimised winding heads or the patented Additive Drives NextPin!
The conductor design is always determined on a customer-specific basis. Every conductor geometry is as unique as its application!
Prototyping
The globally unique production of 3D-printed electric motors makes it possible to manufacture specialized electric drives in the shortest possible time. At the same time, the conventional production of hairpin stators using bending and welding processes is possible at any time.
Testing
We support our customers not only during development and production, but also during testing. Our customers receive validated values on performance, efficiency and other key data within a very short time. In addition to short-term tests, we can also carry out environmental, EMC, service life and functional tests for motors with up to 30,000 rpm and 500 kW.
Function tests:
– Electrical
– Thermal
– Oil cooling
– Max. speed
– Max. power/continuous power
– NVH
– Efficiency
Environmental tests
EMC tests
Lifetime test