Complex Shaped Magnets for an Efficient Use of Rare Earths in Synchro-Reluctant Machines

In order to maximize the torque of Permanent Magnet assisted Synchronous Reluctance (PMaSynRel) machines, sintered magnets should ideally exhibit curved shapes. Standard process fails to produce such geometries without large critical material loss during machining. The Powder Injection Molding technique has been assessed in this work as an efficient process for producing complex shaped magnets while minimizing the environmental impacts and improving the recyclability of end-of-life products. A case study suited for the automotive sector is presented.