Session: 03-03-01: Annual Congress-Wide Symposium on Additive Manufacturing I

Paper Number: 165960

Low Cost Additive Manufacturing of Segmented Stator Composite Polymer Permanent Magnet DC Motors 

This work presents a novel strategy for designing, manufacturing, and optimizing segmented stators in composite construction axial flux permanent magnet DC motors. By dividing the stator into discrete segments, each segment can be fabricated using advanced polymer-based composite materials and cost-effective additive manufacturing methods. This modular approach significantly lowers production complexity, which traditionally hinders rapid prototyping efforts for axial flux machines. One of the core benefits of this segmented strategy is the ability to customize coil geometries to maximize surface area and improve heat dissipation. Each segment can be tailored with specific dimensions and winding densities based on the application’s power and torque requirements, leading to enhanced thermal performance and reduced risk of overheating. Furthermore, the segmentation allows for straightforward assembly and maintenance, enabling designers to replace or modify individual segments without re-engineering the entire stator.

A key innovation introduced here is a dielectric ferrofluid cooling system integrated into the segmented stator assembly. This system addresses the challenges associated with thermal management in non-iron core stators by efficiently transferring heat from the electromagnets to the rotor. This transfer mechanism stabilizes operating temperatures, mitigating the adverse effects of thermal buildup during high-load conditions and continuous operation. Early experimental data suggest that this approach boosts thermal efficiency, increases power output, and enhances overall motor stability.

The segmented design paves the way for rapid design changes, making it highly attractive in research and industrial contexts. Engineers can quickly iterate to refine winding patterns, overall stator shape, and cooling flow paths, while also pursuing weight and size reductions to meet specific performance targets. This adaptability proves especially valuable for diverse applications ranging from electric vehicles to aerospace systems, where compactness and efficiency are critical. Moving forward, ongoing research will concentrate on refining both the ferrofluid cooling process and the geometries of individual stator segments. There is considerable potential to leverage additive manufacturing’s flexibility by experimenting with new materials and surface treatments that further enhance thermal performance and mechanical robustness. Ultimately, this scalable, modular approach to axial flux motor design stands poised to revolutionize the speed and efficiency of next-generation electric motor development.

In parallel, advanced computational modeling can optimize magnetic flux distribution across each segment. This data-driven approach enables fine-tuning of parameters like coil turns, conductor thickness, and ferrofluid viscosity for improved performance. Integrating sensor arrays within each segment also facilitates real-time monitoring of temperature, vibration, and magnetic field density, enabling smarter control strategies.

Presenting Author: Ben Goldberg Kennesaw State University

Presenting Author Biography: I am a Junior Mechatronics Engineering student with a Decade of active hobbyist and industry experience in vast spans of fields, from Embedded Systems, Power Electronics, Autonomous Robotics, Machining, Manufacturing, and Multi-Material Fabrication. I have developed multiple unique manufacturing methods and actively work on expanding the field of low barrier-to-entry axial flux motor development and refinement.

Authors:

Ben Goldberg Kennesaw State University
Jordan Bailey Kennesaw State University
Colin Haskins Kennesaw State University
Connor Hawkins Kennesaw State University
Rasvan Voicu Kennesaw State University