Electric motors are composed of laminated sheets of FeSi3, separated by insulating polymer layers. The ferromagnetic material FeSi6.5 has lower magnetic losses than FeSi3, making it a promising candidate for the manufacture of electric motors. However, its high silicon content complicates its production by conventional lamination processes. Additive manufacturing offers a viable alternative, but it is currently limited to single-material structures. Research on multi-material additive manufacturing is still in its early stages. The challenge is to manufacture laminated electric motors using additive manufacturing with thin ceramic insulating layers and FeSi6.5 layers. We have developed a system to modify our LPBF machine for bi-material processes and to optimize the ceramic/metal interface.
AMITOUCHE et al. (Tue,) studied this question.