article · Energies
Metal additive manufacturing provides substantial flexibility and eliminates material waste, allowing for novel designs with superior material efficiency that conventional machining methods cannot achieve. A review of these technologies assesses different metal additive manufacturing methods suitable for various uses, particularly the fabrication of electrical machines. It compares distinct techniques and examines how using powder or wire feedstock influences both printing speed and output quality. Drawing from industrial and technical sources, the current state of the art illustrates how additive manufacturing is being adopted in the production of electrical machines, highlighting the operational advantages and design possibilities that modern processes bring to electromagnetic equipment manufacturing.
Conventional manufacturing of electrical machines often produces significant material waste and restricts geometry options. Metal additive manufacturing offers a cleaner production alternative that reduces scrap while permitting complex, efficient geometries. Understanding the trade-offs between different processes and feedstocks helps manufacturers evaluate new approaches for producing high-performance electromagnetic equipment.
The technology is relevant to manufacturers and designers of electrical machines looking to replace or supplement subtractive machining with additive methods. While additive manufacturing itself is in commercial use across industries, its specific deployment for electrical machine fabrication spans from applied research to industrial testing, depending on the chosen technique and whether powder or wire feedstock is used.
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Metal additive manufacturing (AM) has been growing remarkably in the past few years. Thanks to the advantages of unmatched flexibility and zero material waste, this clean technology opens the door for new design solutions with greater material efficiency, which are not possible through conventional machining techniques. In this paper, we provide a technology overview of metal AM techniques that can be utilized in a wide range of applications, including constructing electrical machines. Different techniques of metal AM are discussed and compared. Additionally, the impact of the material forms (powder/wire) on printing speed and quality are studied. Based on the industrial and technical literature, this paper provides a comprehensive review of metal AM in the fabrication of electrical machines and their applications. This includes the current state of the art and associated benefits of AM in these applications.
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DOI: 10.3390/en15031076
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