Method for Additive Manufacturing of a Three-Dimensional Component with at Least One Winding

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This invention relates to an additive manufacturing (3D printing) method for producing three-dimensional components with at least one winding, such as coils for electric machines (e.g., motors or generators). The process involves applying build material layer by layer and selectively solidifying it using a directed energy source (like a laser or electron beam) to create windings of precise, often very thin dimensions (down to ≤0.5 mm) with highly controlled geometry. The method also allows the windings or coils to be elastically stretched or compressed for easier post-processing, such as cleaning, polishing, and applying electrical insulation.

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• Manufacture of compact coils and windings for electric motors and generators using additive manufacturing.
• Production of customized or prototype electromagnetic coils with specialized geometries and thin cross-sections for research or industrial applications.
• Integration of winding elements into complex electrical assemblies with space-saving design.
• Simplified post-processing, cleaning, and insulation of coils used in industrial machinery.
• Efficient small-batch or individualized production of stator windings for customized or high-performance electric drives.

BenefitsContent extracted from patent full text and abstract with AI.

• Enables highly space-saving and compact winding (coil) designs, maximizing fill factor and performance of electric machines.
• Allows for precise control over winding thickness and structure (down to ≤0.5 mm), improving electrical efficiency and reducing losses like skin-effect and eddy currents.
• Facilitates rapid prototyping and easy customization without the need for new tooling or wire winding equipment for each design.
• Simplifies post-processing such as insulation, cleaning, and polishing, thanks to the ability to stretch coils elastically during these steps.
• Reduces mechanical stresses and deformation common in conventional winding techniques, maintaining material conductivity and integrity.
• Enhances flexibility in the choice and application of insulation systems, supporting both liquid and solid types for better dielectric properties.
• Permits innovative coil geometries not possible with traditional manufacturing, improving cooling and integration within electric machines.

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Patent Abstract

The invention relates to a method for additively manufacturing a three-dimensional component having at least one winding, in particular a coil (17) for an electric motor, by layer-by-layer application of a construction material and locally selective solidification of the construction material by irradiation with at least one beam impinging on the construction material, wherein the irradiation is configured in such a manner that a thickness of the winding at least in sections is less than or equal to 1.0 mm, preferably is less than or equal to 0.5 mm, and/or wherein at most ten, preferably at most five, furthermore preferably at most two irradiation paths lie next to one another, or there is precisely one irradiation path, at least in sections in a thickness direction.