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BOTTOM LINE UP FRONT:
MOTORPRINTER is a patented hybrid 3D Printer of the highest performance electromagnetic axial-flux cores with integral frame and winding assemblies for low or high frequency, high power, electric motors, electric generators, or electric transformers (i.e., electric machines).
MOTORPRINTER additively manufactures magnetic cores with: 1) optimally pre-manufactured and readily available high performance amorphous metal or nanocrystalline ribbon, which provide 10x the permeability and 80% lower core loss than electrical steels with comparable flux saturation constraints, 2) integral structural frame with optimally pre-manufactured and readily available high performance structural building materials, and 3) winding assembly with readily available magnetic wire.
MOTORPRINTER eliminates the high capital cost of electric machine manufacture in order to democratize the global manufacture of high performance axial-flux electric machines with portable, scalable, low waste, non-smokestack, additive manufacturing.
MOTORPRINTER is essential for manufacturing high power, high frequency magnetics (e.g., transformers) with the highest performance magnetic materials, which is essential for: a) leveraging the switching speed, high temperature performance of wide bandgap semiconductors, which is essential for high efficiency and compact power conditioning, b) for automatic frequency and phase translation, such as only provided by a position dependent flux high frequency transformer of Brushless Real Time Emulation Control (BRTEC), and c) for implementing the only symmetric synchronous electric machine system, called SYNCHRO-SYM.
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 BEM-CAD programmable size or power rating: 1) with readily available, environmentally friendly, and optimally pre-manufactured materials that are specially made for electric machine products, such as ultrathin nanocrystalline, amorphous, or electrical steel ribbon, instead of less optimized electromagnetic materials that are exclusively manufactured to be compatible with the 3D Printer, itself, 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 operations, such as Blanchard grinding for a precision flat air-gap surface, 5) without tool wear, and 6) with accommodating frame and winding assemblies from inexpensive, readily available, optimally pre-manufactured, high performance structural steel, aluminum, or composite building materials, instead of the traditional inventory of pre-designed and pre-ordered casted components, and magnetic wires.
NOTE: Electric machines, which include compact and efficient high frequency transformers, are the essential backbone components of the entire electricity infrastructure. Magnetic core material with high flux saturation limits, high permeability, and low core loss that can be conveniently manufactured into high power, high frequency cores is essential. Insulated membrane powdered magnetic materials, such as ferrite, show low permeability, low flux saturation limits, and are difficult to structurally form in the large size factor for high power applications. In contrast, evolving material science is improving nanocrystalline or amorphous metal ribbons for high power cores from 10s of khz to mhz operation while preserving low loss, high flux saturation, and high permeability but still, manufacturing of moderately complex transformer cores with these materials has not been practical. As the only empirically proven laminated object manufacturing (LOM) 3D Printer with amorphous or nanocrystalline metal ribbon, the patented MOTORPRINTER is an essential enabler of the nanocrystalline metal ribbon transformer core and 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 manufacture of electric machines by mitigating unfair trade practices, such as oppressed labor, and by conveniently localizing rapid just-in-time 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 pre-manufactured raw 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 and optimized manufacturing for the highest electric machine efficiency and smallest size, such as amorphous metal ribbon.
NOTE: Although virtually the entire base of rotating electric machine manufacturing is devoted to the radial-flux form (or rotor cylinder inside a stator cylinder form) because of traditional manufacturing technology limitation, the axial-flux form of electric machine (or adjacent stator and rotor disks) has been shown to reduce copper utilization by 13-14% and iron utilization by 21.5-32.5%, while providing higher torque density and finer air-gap depth control without rotor and stator surface contention during over speed but requires a more robust frame and bearing assembly.
NOTE: The axial-flux formfactor provides a non-obstruction outside-to-inside winding approach for automation of any winding style with the potential for orthocyclic winding fill factor (e.g., 90%). In contrast, the radial-flux inside-to-outside winding approach is not friendly to automated winding, except for the hairpin winding style, which may provide a high fill factor (e.g., 90%) and efficiency at low speeds. MOTORPRINTER’s axial-flux formfactor at least neutralizes any perceived advantages of hairpin windings, while providing rapid, just-in-time additive electric machine manufacture.
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 bezel assembly. Specifically for SYNCHRO-SYM, BEM-CAD also provides a selectable mode that optimizes the wound, 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.
Where other electric machine manufacturers simply repackaged their electric machine system from off-the-shelf cores, castings, etc., BEM is fabricating its patented 3D Printer of amorphous metal axial-flux electric machine cores with integral frame and active windings for the just-in-time, additive manufacture of SYNCHRO-SYM.