Additive manufacturing of 3D magnetic circuits
Additive manufacturing has been revolutionary in enabling complex structural components, however, the utilization of functional materials such as soft-magnetic materials is relatively immature. 3D magnetic circuits in electrical machines have been elusive due to the high eddy current losses caused by thick cross-sections in bulk material, and the inability to process electrical steel laminations into 3D structures. By processing soft magnetic materials with additive manufacturing, geometry can be tailored to avoid thick cross-sections and reduce eddy currents whilst maintaining a 3D magnetic circuit, enabling new machine architectures that can meet the power density targets for the electrification of aviation.