MOTORPRINTER

MOTORPRINTER Details

BOTTOM LINE UP FRONT:

MOTORPRINTER is a patented hybrid 3D Printer of  the highest performance electromagnetic axial-flux cores with integral frame assembly for low or high frequency, high power, electric motors, electric generators, or electric transformers (i.e., electric machines).

MOTORPRINTER additively manufactures cores with optimally pre-manufactured and readily available high performance amorphous metal ribbon with 10x the permeability and with 80% lower core loss then electrical steels and frames with optimally pre-manufactured and readily available high performance structural building materials.  

MOTORPRINTER eliminates the high capital cost of electric machine manufacture and democratizes the global manufacture of high performance axial-flux electric machines with portable, scalable, low waste, non-smokestack, additive manufacturing.

DETAILS:

MOTORPRINTER is a patented “method” for rapidly and additively manufacturing ultrahigh performance, low or high frequency, high power axial-flux electric motor, electric generator, and electric transformer cores (or axial-flux “electric machine” cores) of any size or power rating: 1) with readily available, environmentally friendly, optimally processed materials that are specially made for electric machine products, such as ultrathin nanocrystalline, amorphous, or electrical steel ribbon, instead of compatibility with the 3D Printer as all others, 2) with perfectly aligned slots and slot channels of any programmed shape (for containing windings, permanent magnets, reluctance saliencies, etc.), 3) without damaging the delicate attributes of the pre-processed high performance materials, such as amorphous metal ribbon, 4) without the extraneous time and cost of secondary or post-process machining operations, such as Blanchard grinding for a precision flat air-gap surface, and 5) without tool wear; and for additively manufacturing the accommodating frame and bearing bezel assembly with inexpensive, readily available, optimally processed, high performance structural steel, aluminum, or composite building materials, instead of the traditional inventory of pre-designed and pre-ordered casted components.

Since electric machines, such as compact and efficient high frequency transformers, are the essential backbone components of the entire electricity infrastructure, such as for emerging renewable energy, the smart grid, electric vehicles, micro-distribution buses, etc., MOTORPRINTER will be an essential enabler of the future performance of the smart electricity infrastructure.

NOTE: As a patented “method,” which protects the manufacturing IP and more importantly, the product manufactured with the IP, MOTORPRINTER will democratize the distributed manufacturing of electric machines by mitigating unfair trade practices and by conveniently localizing electric machine manufacturing at the research facility, at the boutique motor manufacturing facility, or at the traditional OEM manufacturing facility.

NOTE: Unlike all other 3D Printers, which utilize specially processed materials to be specifically compatible with the 3D Printer without regard to the product being 3D Printed, MOTORPRINTER rapidly 3D Prints axial flux electric machines just in time by directly using readily available pre-manufactured materials with the highest performing electromagnetic and structural properties for the highest electric machine efficiency and smallest size, such as amorphous metal ribbon.

MOTORPRINTER performance with amorphous metal ribbon has been empirically studied and successfully proven through the formulation, orchestration, and coordination of BEM with the original inventor and foundry of amorphous metal ribbon (i.e., Metglas) and with several fiber laser companies (e.g., IPG Photonics). More information can be found in the MOTORPRINTER whitepaper and a study by Metglas.

Also, BEM developed a Computer Aided Design tool (BEM-CAD) for the design and MOTORPRINTER manufacture of axial flux electric machine cores with integral frame and bearing assembly. Specifically for SYNCHRO-SYM, BEM-CAD also provides a selectable mode that optimizes the axial flux core and frame design for optimally placing active cooling vents and brushless real time emulation control (BRTEC) within the otherwise wasted annulus space of the axial flux core for an additional level of motor power density and cost reduction.