Feasibility study on design and manufacture of electrical windings for electrical vehicles via additive manufacturing of copper (DEMAM)

Nowadays, the automotive industry is shifting towards electric vehicles to reduce the CO2 emission and global warming. Therefore, the engineers are challenged to create superior electric vehicles with improved motor efficiencies. This can be enabled by new design for critical components, such as more complex electrical windings in motors.

Since manufacture of such complexity may not be possible using the conventional techniques, new methods such as additive manufacturing (AM) are required.

Accordingly, our interdisciplinary team from KTH, Xylem and Scania with production and electrical engineering background will explore the possibilities of designing and producing AM electric motor windings for electric vehicles from copper using electron beam melting (EBM). The ultimate goal is to increase the power and energy efficiency of electrical motors with our innovations.