Fully 3D‐Printed Wave‐Wound Electromagnetic Motors

Additive manufacturing has become an enabling technology, but existing techniques are not capable of directly 3D printing high current electromagnetic actuators due to material and design limitations. In this work, a novel 3D‐printable, multi‐layer, wave‐winding topology is created for high efficiency electric motors. This is achieved through the development of a new additive manufacturing technique that incorporates conductive silver nanoparticle inks, thermally conductive but electrically insulating polymers, and surface mount electrical components. Excluding the permanent magnets, this work is the first to demonstrate the use of 3D printing for manufacturing all of the motor elements. This includes the stator, housings, bearings, and sensing circuits for an axial flux motor, cylindrical radial flux motor, and a linear motor. Results show that the axial flux motor can reach a peak stall torque of 7.62 and a maximum efficiency of 28.2%, which is 5 higher torque and 3.7 higher efficiency than any prior work. Using these unique 3D printed actuators, realistic applications are demonstrated including a fan, water pump, paddle‐wheel boat, multi‐legged walking robot, and waving arm. With the material and design innovations discussed in this work, the creation of fully 3D‐printed electromechanical devices, machines, and robots become possible.