A Review on Properties of 3D Printed Magnetic Cores for Electrical Machines: Additive Manufacturing Methods and Materials

Additive Manufacturing (AM) is a new topic in the field of electrical machines (EMs), offering the potential to overcome the limitations in the design of EMs. Through AM, complex 3D geometries and the utilization of Fe-Si cores with 6.5% silicon can be achieved, leading to enhanced EM performance without concerns about manufacturing cost and complexity. This paper provides an overview of various AM methods and materials used in manufacturing soft magnetic cores for EMs, with a particular emphasis on the multi-physics properties of these cores. Due to the distinct fusion processes in each AM method, the microstructural properties of the printed cores vary, leading to diverse multi-physics properties that require detailed investigation. The paper outlines both the benefits and challenges associated with AM techniques and materials. Importantly, it explores the detailed characteristics of Fe-Si and Fe-Co cores manufactured through different AM methods, comparing them with commercial laminations such as 35A300, JNEX Super Core, and Hiperco 50A.