With the selective laser melting of copper (“copper 3D printing”), Additive Drives helps you to reach electrical conductivity of 100% IACS (International Annealed Copper Standard, 58 MS/m)
a basic requirement for our target application, electric motors performing at their highest efficiency levels.
The drive tasks of the future, whether in industry or traffic, place high demands on individual components. Conventional electric motor manufacturing processes quickly reach their limits; optimized geometries for electric motor functionality often cannot be attained. This leads to painful compromises in performance and efficiency.
This problem is solved using 3D printing to manufacture copper coils. The higher copper content in the electric motor reduces losses and improves the thermal coupling of the winding.
A 45% performance increase was registered when our copper coils were used in a racing motor.
Electrochemical post-processing enables tailorable surface roughness, while electrical insulation processes ensure an improved thermal connection of the winding to the laminated stator.
We are focusing on hairpin windings, currently the most popular design in the automotive industry. The typical delivery time for hairpin winding prototypes is at least six months, partly due to tools used for the production of windings. We offer significantly reduced prototype delivery lead times of a few weeks.
Coils that we printed and applied in a racing motor yielded an electric motor power increase of 45%. This was made possible by an optimal design of the winding geometry.