3D printing motors on

The theoretical example of a high flying executive, having arrived at the latest in a string of top international hotels, donning a pair of fully personalised 3D printed trainers that were produced onsite, (presumably so said executive could go and run an ultramarathon or something in between important meetings) has been alluded to at more than one event I have attended. While this scenario doesn’t really work for me - Why couldn’t they just remember to pack their trainers in the first place? They are obviously not very organised even if they are a high flying executive! - I can appreciate its vision and sense of ambition.

In my view, however, a much more inspiring example of how 3D printing can be transformational is the development of an electric motor made from 3D printed components by a team of experts at the Coventry-based Manufacturing Technology Centre. Apart from the fact that this is something that has actually been achieved and is not just part of a futuristic demonstration, what is really impressive is that result is a motor with increased motor power despite a reduction in the size and mass of key components, a part count reduction (making supply chains simpler - and God knows we all need that at the moment), increased manufacturing efficiency, lower running costs and reduced assembly and inspection time and costs.

MTC chief technologist Steve Nesbitt has gone so far as to say the development of electric motors hadn't received this level of focus for more than 100 years, despite costs, quality and performance being high on manufacturers' priority lists.

“Additive manufacturing is a key enabler for developing the complex features and forms essential to improving the performance and functionality of electric motors,” he said.

“The process of manufacturing electric motors has a number of challenges including complex or manual assembly, materials that are difficult to process and which can be expensive, thermal management, and the need to make the assembly lighter. By leveraging the capabilities of additive manufacture through product redesign major benefits can be achieved in costs, waste reduction, performance and ease of manufacture.”

The MTC's experts are now involved in a detailed examination of further developments required for production, and overcoming potential challenges and constraints.
 
If you are interested in finding out more about the MTC's 3D printed electric motor head to: www.the-mtc.org