Novel 3D Printed Coils for High Power Density Electrical Machine and Traction Applications

Nowadays, manufacturability challenges are limiting the performance of electrical machines. With the emergence of additive manufacturing (AM) technology, new design solutions are becoming applicable which were not possible to achieve using conventional production techniques. This work addresses unconventional design possibilities in the manufacturing of machine windings. Using 3D printing technology, a new coil is designed and prototyped for high power density electrical machines. Targeting traction applications, the proposed design combines higher performance and easier manufacturability. Moreover, a new thermal management approach is introduced using a novel AM shaped profile coil which allows for high electromagnetic as well as thermal performance.