DAC102021

n TECHNOLOGY October 2021 www.drivesncontrols.com 26 TWO US COMPANIES have developed a new way of producing copper windings for motors using 3D printing techniques that, they say, eliminate many of the limitations of traditional techniques for manufacturing windings. Pennsylvania-based ExOne, which specialises in 3D metal and sand printers using a binder jetting technology, is collaborating with a Tennessee-based start- up called Maxxwell Motors to develop “unique” copper windings for Maxxwell’s axial-flux motors, which avoid the need for magnets and rare-earth materials. Current methods of manufacturing motor windings are costly, inefficient, and limit their design and performance. ExOne and Maxxwell say that their binder jet 3D printing of high-efficiency copper windings eliminates many of the challenges associated with traditional production. Windings produced using the new process need fewer manufacturing steps, use less energy, and result in less waste material. They are also claimed to be more efficient and to improve performance. “When we 3D print it, a lot of the challenges just go away, and we can actually improve the performance of the motor itself,” explains Maxxwell’s CEO, Michael Paritee. “We’re taking the most sustainable, and additive manufacturing, point-of-view as possible to truly improve efficiency, reduce waste and optimise performance.” Maxxwell was founded in 2018 with the aim of improving the design and manufacturing of electric motors without using rare-earth magnets. The company holds nine US and global patents and has launched two products – a 10kW air-cooled motor-generator, and a 150kW liquid-cooled motor. Additional development and testing are now underway, with Maxxwell’s goal being to 3D-print winding assemblies as monolithic pieces, eliminating coil wrapping, bending and tooling processes, as well as the need to weld individual parts together. ExOne’s binder jet 3D printing technology transforms powder materials – including metals, ceramics, composites and sand – into precision parts, metal-casting moulds and cores, and tooling. It is said to save time and money, reduce waste, improve manufacturing flexibility, and to deliver designs and products that were previously considered impossible. www.maxxaf.com www.exone.com 3D printing of motor windings eliminates drawbacks ExOne and Maxxwell Motors say that their 3D printing technology results in high-efficiency copper windings that avoid many of the drawbacks of traditional coil manufacturing techniques. Image: BusinessWire 22 5-7 APRIL 2022 HALLS 9 & 10 NEC BIRMINGHAM 85%BOOKED! #PlantAssetExpo www.maintenanceuk-expo.com S E C U R E Y O U R S T A N D N O W Damien Oxlee +44 (0) 1732 370342 damien.oxlee@dfamedia.co.uk Georgie Turner +44 (0) 1732 371084 georgie.turner@dfamedia.co.uk IN ASSOCIATION WITH: CO-LOCATED WITH: The UK’s premier event for plant, asset, maintenance and works management engineers and directors SPONSORS S O F T W A R E S O L U T I O N S Talking Industry PAM 2022 Half Horizontal Book Now.qxp_Layout 1 04/08/2021 08:47 Page 1