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MOTORPRINTER

MOTORPRINTER

Only Practical Electric Motor and Generator 3D Printer Method

Our Mission –

Innovate For Our Clean, Efficient, and Sustainable Energy Future!


BOTTOM LINE UP FRONT:

MOTORPRINTER is a patented 3D Printer for the just-in-time additive manufacture of the highest performance electromagnetic axial-flux cores with integral frame and winding assemblies for low or high frequency, high power electric motors, generators, and transformers (i.e., electric machines).

MOTORPRINTER uniquely layers readily available materials that are optimally pre-manufactured to be ultra price-performance enhanced: 1) for the electric machine magnetic core component, such as ultrathin, high performance amorphous metal or nanocrystalline metal ribbon that provides 10x the permeability and 80% lower core loss than electrical steels but with similar flux saturation, 2) for the integral structural frame component, such as high performance structural building materials, and 3) for the multiphase winding component, such as high performance shaped magnetic wire.  In contrast, layering material of all other 3D Printers is optimally pre-manufactured to be price-performance compatible with the 3D Printer and not for the product being manufactured. As a result, a practical electric motor 3D Printer has never materialized until MOTORPRINTER.

MOTORPRINTER eliminates the high capital equipment, offshored oppressed labor, and large facility costs of traditional century old, assembly line electric machine manufacture with a portable, scalable, low waste, non-smokestack, compact, remotely controlled, additive manufacturing footprint (e.g., shipping container).

MOTORPRINTER is essential for manufacturing high power, high frequency magnetics (e.g., transformers) with the highest performance magnetic materials: a) for leveraging the switching speed, high temperature performance of wide bandgap semiconductors, b) for facilitating high efficiency and compact power conditioning, c) 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 d) for implementing the only symmetric synchronous electric machine system, called SYNCHRO-SYM.

MOTORPRINTER is essential for solving the manufacturing production and thermal management challenges and the structural, permeability, and flux saturation limits of soft magnetic material, such as found in RE-PM YASA style electric motors, with the unique ability of forming perfectly aligned slots and channels of any programmable shape for windings, permanent magnets, reluctance saliencies, or thermal management in high permeable and structural solid nanocrystalline or amorphous ribbon materials.

MOTORPRINTER revolutionizes and democratizes the manufacture of axial-flux high frequency and low frequency electric motors, generators, and transformers with a rapid, just-in-time, compact, scalable, low waste, non-smokestack, remotely controlled, self-contained 3D Printing method, which provides a competitive advantage over all other electric machine manufacturers.


DETAILS:

MOTORPRINTER is a patented “method” for rapidly and additively manufacturing ultrahigh performance, low or high frequency, high power axial-flux electric motor, generator, and transformer cores (i.e., axial-flux “electric machine” cores) of any programmable size or power rating: 1) with readily available, environmentally friendly, and optimally pre-manufactured layering materials that are exclusively made for the performance of the electric machine product, such as ultrathin nanocrystalline, amorphous, or electrical steel ribbon, magnet wire, and structural materials, instead of traditional layering materials that are specifically manufactured for compatibility with the 3D Printer, 2) with perfectly aligned slots and internal 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, tool wear, material damage, 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 winding and integral frame assemblies from inexpensive, readily available, optimally pre-manufactured, high performance magnet wire and structural steel, aluminum, or composite building materials, instead of the traditional inventory of pre-designed and pre-ordered casted components.

NOTE: Electric machines, which include compact and efficient high frequency transformers, are the essential backbone components of the entire electricity infrastructure. Furthermore, magnetic core material with high flux saturation limits, high permeability, and low core loss that can be conveniently manufactured into high power, high frequency magnetic cores is essential. Evolving material science is improving nanocrystalline or amorphous metal ribbons for high power, high frequency cores 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. Also, soft magnetic composite materials, such as ferrite, show low permeability, low flux saturation limits, or are difficult to structurally form in the large size factor for high power applications. As the only empirically proven laminated object manufacturing (LOM) 3D Printer for electric machines with solid amorphous or nanocrystalline metal ribbon, the patented MOTORPRINTER is an essential enabler 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 offshoring for low cost oppressed labor, and by conveniently localizing and scaling 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 that are optimized to the lowest cost and highest performing electromagnetic and structural properties 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.

NOTE: Under design control of BEM’s computer aided design tool (BEM-CAD), MOTORPRINTER simultaneously 3d-Prints the high frequency power magnetic core of the electronic power conditioner conveniently integrated into the annulus of the low frequency axial-flux electric machine core for another level of electric machine system power density. In contrast, all others electric motor manufacturers place the entire power electronic real-estate, which includes the high frequency magnetics, of the so-called smart motor system in a separate box chassis mounted on the outside of the electric motor frame.

NOTE: Where other electric machine manufacturers traditionally repackage and manufacture their me-too asymmetric electric machine system from the same off-the-shelf core stamped laminations, castings, etc., BEM is just-in-time, additively manufacturing the only symmetric synchronous doubly-fed electric machine system, called SYNCHRO-SYM, with its patented 3D Printer of amorphous metal axial-flux electric machine cores with integral frame and winding assemblies, called MOTORPRINTER.

NOTE: With the unique ability of forming perfectly aligned slots and channels of any programmable shape for installing windings, permanent magnets, reluctance saliencies, or thermal management in high permeable and structural solid nanocrystalline or amorphous ribbon materials, the manufacturing production and thermal management challenges and the structural, permeability, and flux saturation limits of soft magnetic material, such as found in RE-PM YASA style electric motors, are solved

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, the foundry of amorphous metal ribbon (i.e., Metglas), and 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 programming of MOTORPRINTER manufacture of axial flux electric machine cores with integral frame, bearing bezel, and winding assembly.


It follows that being compatible with available, highly optimized, premanufactured layering material, MOTORPRINTER fabrication, integration, and manufacturing operation has no risk without the customary engineering solution.

MOTORPRINTER revolutionizes and democratizes the manufacture of axial-flux high frequency and low frequency electric motors, generators, and transformers with a rapid, just-in-time, compact, scalable, low waste, non-smokestack, remotely controlled, self-contained 3D Printing method, which provides a competitive advantage over all other electric machine manufacturers.


PRODUCT → WHITE PAPERS: