The original rare earth permanent magnet (RE PM) and back-iron disks of high permeable core materials, which are required to complete the magnetic path through the air gap, should be replaced with similar dimensioned back-iron disks of low core loss laminated electrical steel (because the rotor is now actively contributing to electromechanical power production). Although SYNCHRO-SYM can retrofit MAGNAX’s Yokeless and Segmented Armature (YASA) form with concentrated windings, SYNCHRO-SYM prefers a simpler NN-Torus-S form for better cooling, better structural robustness, but more importantly, for accommodating the rapid additive manufacture of axial flux electric machines with high performance amorphous metal ribbon (as only provided by MOTORPRINTER) for an additional level of motor efficiency.  Also, BEM developed a Computer Aided Design tool (or BEM-CAD) for SYNCHRO-SYM that optimizes the axial flux core design for the convenient placement of active cooling vents and brushless real time emulation control (BRTEC) within the otherwise wasted annulus space of the axial flux core between the outer diameter of the axial bearing bezel and the inner diameter of the axial-flux magnetic core (including end turns) for an additional level of motor power density.



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