Electrical motors are typically made by cutting and moulding pieces from a metal sheet. 3D printing provides an option to increase efficiency and reduce material consumption. However, printing larger motor parts has proven more difficult, as the parts often become too brittle and may break.
Chemicals company Elkem and its project partners VTT, Siemens, Stellantis, and Gemmate Technologies have developed a solution. Through an EU-funded project called SOMA (lightweight solutions for e-mobility by AM for soft magnetic alloys), the partners developed a new specialized iron silicon powder, which may allow 3D printing of components for electrical motors.
The powder is called “soft magnetic” because it’s easy to magnetize and de-magnetize, which is important in electrical motors. It’s produced in a small-scale pilot atomizer and has been used to 3D-print components for evaluation of the quality and manufacturing of demo devices. The 3D printing and part qualification have been done at VTT in Finland and Siemens in Germany.
“This is a project with the potential to transform motor parts manufacturing. We have successfully created a new specialized powder with good printability based on silicon-steel (with additives). 3D-printed components show enhanced ductility and competitive magnetic properties,” said Tomi Lindroos at VTT.
The final use-case was to produce a motor for an electric scooter. The use-case was supported by modelling carried out by Gemmate-Technologies and VTT giving more novel design opportunities for electrical motor components.
“The powder developed in the SOMA project will now be introduced to the market by Elkem for evaluating the product for future commercial production. The product is currently available in small test volumes,” said Jan Ove Odden, project leader with Elkem.
As the world shifts toward more sustainable modes of transportation, electrification has become a key priority for automakers, governments, and consumers alike. Elkem is one of the world’s leading providers of advanced silicon-based materials and will continue to provide silicon based products across mobility and transportation sub-sectors.
The three-year project, which started 01.01.2021, was supported by EIT Raw Materials, funded by the EU with a total project budget of just over 5.6 MEUR.
Filed Under: Technology News