comingSoon – 3D printed engines

Electric motors are becoming very popular in the automotive world, with companies around the world vying for a slice of the EV pie.

And with that demand comes innovation. Engines themselves haven’t changed much in terms of design since they were invented, but recent advances have led engine designers to apply new methods to increase performance and reduce weight.

There are already companies using additive manufacturing in the production of electric motors. One of the most visible examples is the 3D printed copper motor coil from German company Additive Drives.

Researchers at the Manufacturing Technology Center (MTC) in Coventry, UK, recently developed an engine with even more 3D printed components, specifically 3D printed cooling systems.

Much of the project focused on developing workflows and evaluating both the technical readiness level (TRL) and production readiness level (LMR) of the project.

You can see one of the 3D printed engines in the image below. Note the fluid inlet/outlet and cross cooling channels in the case.

By implementing liquid cooling channels in the motor housing, the motor has been proven to produce more power without overheating and benefits from a 10% weight saving and 30% size reduction.

“The development of electric motors has not seen this level of attention for almost 100 years, despite being high on the priority list for many industrial sectors seeking significant improvements in cost, quality, reliability and performance, both gravimetrically and volumetrically.” said Steve Nesbitt, MTC chief technologist.

“Systems engineering and integration – i.e. doing more with key components and materials – are essential to achieve this, and therefore additive manufacturing is a key enabler for developing complex features and shapes essential to improve the functionality and performance of electric motors, with single and multi-material solutions.”

The electric motor manufacturing process presents a number of challenges to overcome; complex or manual assemblies, materials that are difficult to work with and may be rare and/or expensive, thermal management and lightness.

The molded motor housing design has demonstrated a number of benefits, including increased motor power density, reduced component count, increased manufacturing efficiency and shortened lead times, lower operating costs and reduced waste.

In summary, the results so far have enabled MTC and its colleagues to develop a roadmap and review DfM/DfA for the development of 3D printed engines and have identified areas of research to focus on.