New Hybrid Stator Design for High-Speed PMSMS Based on Selective Laser Melting of 3-D Printing

In this paper, a new hybrid stator fabrication with 2-D steel sheets lamination and 3-D end cap structure for high-speed motor application is provided. With the additional overhead end cap design, the new motor not only features lower iron losses in high frequency and reduces copper losses like traditional soft magnetic composite (SMC) motor but also achieves higher permeability and lower production cost at the same time. In this paper, the motor characteristics, i.e., back electromotive force and efficiency between the traditional lamination, SMC, and the new hybrid design are investigated by 3-D FEA simulation. Moreover, a prototype is fabricated by 3-D printing for the verification of the analytical and simulation results.