Challenges of Additive Manufacturing of Electrical Machines

3D printing or additive manufacturing (AM) technology is considered an essential component of the Industry 4.0 revolution due to its improved capabilities over traditional manufacturing systems, facilitating the shift towards next generation smart factories. The three-dimensional fabrication freedom also suggests a new epoch in the design of electrical machines, as the process can finally be liberated from the constraints of 2D laminations. Despite the multi-material nature of 3D printing electrical machines, due to the availability and maturity of dedicated metal printing systems, most of the research and development on the field is concentrated on material optimization and rapid prototyping on these systems. In this paper we present the challenges of 3D printing electrical machines with current manufacturing systems and solutions offered by different authors. Challenges of selective laser melting (SLM) fabrication are discussed in greater detail due to its recognition and popularity in the electrical machine community.