Making Electric Motors More Efficient, Affordable By 3D-Printing Magnets

A $2.6M project will fine tune an advanced manufacturing approach that opens doors to more power-dense and sustainable magnetic materials.

“Often when we talk about improving EVs, we focus on the battery, but the electric motor is another critical component that warrants attention due to concerns about long-term supplies of raw materials and opportunities for enhancing efficiency,” said project leader, the Herbert C. Sadler Collegiate Professor of Engineering in the departments of Naval Architecture and Marine Engineering and Mechanical Engineering.

In today’s most efficient motors, permanent magnets attached to the spinnable rotor generate the magnetic field, and a soft magnetic core of laminated silicon steels guides the magnetic flux. Nanocrystalline soft magnetic materials are a class of typically iron-based alloys with fine-grained, or nanoscale, crystal structure with unique magnetic properties. They have high permeability, which enables strong magnetization with relatively low magnetic fields; low coercivity, which enables rapid response to magnetic field shifts; and low eddy current losses, which translates to less energy lost in the form of heat.

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