High Efficiency Electrical Machines enabled by a new UK Additive Manufacturing PEMD Supply Chain

The electrification of transport is a vital requirement for the UK to achieve its net zero ambitions by 2050\. The recent Government decision to ban the sale of new ICE vehicles by 2030 has made this even more pressing. Our automotive industry will need to adapt significantly to this change and disruptive innovation will be required to achieve this across the myriad use cases that exist within the UK transport network.

A considerable part of this transformation will be in the refinement of electrical machines and drives, which will need to be lighter, more powerful, and produced in ever increasing quantities. Additive manufacturing (AM) has shown immense potential in improving the power to weight ratio of manufactured motors by the newly possible component geometries offering improved copper losses within the motor. AM also enables rapid prototyping of new designs and trialling of new materials quickly and efficiently.

This project is focusing on the end application of Hydrogen Fuel Cell Compressors for these motors as it is currently a low volume high value market where efficiency is a key driver in a successful product. Giving the perfect niche where AM could be commercially viable.

To achieve this, we will need to develop innovative designs and processes for the development of copper windings in motors. The resultant products will be thoroughly characterised, so their functionality and material performance are understood before the necessary insulation and post-processing to allow their integration into an electrical machine. Finally, these new products will be integrated into a full e-motor assembly and trialled.

This project will demonstrate, for the first time, additively manufactured copper windings for niche automotive applications at commercially viable quantities. The high performance, niche nature of this application will ensure the commercial viability of these products at a competitive price point. A significant outcome of the proposal will be to further exemplify the suitability of this approach by comparing the manufactured products to those currently available and identifying any potential optimisation or cost reductions. This will ultimately define a final cost per unit and process in series alongside an assessment of the possible market size for products in this cost and performance range.

The skills and capabilities developed through this proposal will ensure the UK retains its leading position in additive manufacturing of electrical machine components and underpin the continued strength of our automotive sector as we move towards net zero.