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Development of Yokeless Axial Flux Machine Using 3D-Printed Shape-Profiled Core

Today, Additive manufacturing (AM) offers more feasible solutions to the manufacturing and assembly of electrical machines with complex 3D designs such as axial flux motors. With particular focus on 3D printing of magnetic materials, this paper discusses the development of AM stator core for yokeless and segmented armature (YASA) axial flux machine. Aiming at high frequency core loss reduction, an AM shape-profiled core segment is proposed for a 10 kW YASA machine. Unlike the conventionally-stacked core, the proposed AM core has a better magnetic flux density distribution over its cross section, and consequently lower core losses. Using 3D printing technology, this design combines the manufacturing simplicity and high electromagnetic performance merits, allowing for higher-power density axial flux machines.