Investigation of Additive Manufactured and Extruded Hard-Magnetic Rotors for Surface-Moundet Permanent Magnet Synchronous Machines

The advancements in technology have led to a growing interest in additive manufacturing owing to its numerous benefits such as increased degree of freedom, high flexibility, and material conservation. It has gained particular attention in the production of electrical machines and their active components such as windings, electrical insulation, magnetic core packs, and permanent magnets. This paper investigates the use of three methods, namely fused deposition modeling, cold spray and extrusion, in the production of hard magnetic components for rotors with surface-mounted magnets. The produced magnets exhibit either isotropic behavior or an anisotropy in the radial direction, which results in significant improvements of motor performance, particularly in cogging torque and torque pulsation. A comparative study was conducted through a combination of finite element simulations and experimental tests.