OptiMotor – Development and manufacturing of a highly efficient synchronous reluctance motor (SynRM) using an innovative multi-material printing process and optimized high-performance biopolymer magnets
The goal of the project is to develop a lightweight and energy-efficient synchronous reluctance motor using additive manufacturing. Novel bio-compounds with soft magnetic particles and short fiber reinforcement will be used to specifically optimize the rotor geometry to meet both magnetic and structural requirements.
Project Partners
TECNARO GmbH, FAR-UK, Involute Engineering, Brunel University London
Duration
01.12.2024 – 31.05.2027
Funding authority
Central Innovation Program for SMEs (ZIM) of the German Federal Ministry for Economic Affairs and Climate Action (BMWK)
Motivation
The use of synchronous reluctance motors offers advantages for electric drives by eliminating the need for rotor windings and expensive rare-earth magnets, thereby reducing both material usage and CO₂ emissions. Polymer-based composites with soft magnetic particles, combined with additive manufacturing, also provide significant design flexibility, allowing rotor and stator geometries to be tailored specifically to structural and magnetic requirements. In this way, the project contributes to the development of lighter, more efficient, and more environmentally sustainable drive systems.
Method
The Chair of Carbon Composites (LCC) will develop the structural and material foundation for the additively manufactured SynRM. Based on the compound filaments developed by the project partner, suitable simulation models will first be created to predict mechanical and magnetic properties. These models will then be validated through mechanical and magnetic characterization of the materials. In addition, appropriate multi-material printing strategies will be developed and applied to tailor the geometry and process parameters to the structural and functional requirements. Based on this work, a rotor will be manufactured for use in the final demonstrator.
Acknowledgement
The Chair of Carbon Composites at TUM would like to thank the Federal Ministry for Economic Affairs and Climate Action (BMWK) for funding the "OptiMotor" project under the "Central Innovation Programme for SMEs (ZIM)" (funding code: KK5135830HD4).
Contact Persons
Rodrigo Luengo Scotto, M.Sc.; Dipl.-Ing. Thomas Wettemann