E-MOTIONS - Innovative Magnetic Materials Solution via Additive Manufacturing for E-Mobility Applications
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Abstract
Recent developments in electrical mobility (E-mobility), fuelled by the transition toward environmentally sustainable industrial practises, are driving significant innovations in materials science for motors and related components. In this context, soft and hard magnetic materials are essential for achieving high-performance, compact and efficient systems. However, current solutions still face major limitations, including high eddy current losses, low mechanical and thermal properties, high hysteresis, and insufficient design and volume reduction. The E-MOTIONS project introduces a breakthrough strategy based on the property programming of multifunctional magnetic material through layer-engineered powders processed by additive manufacturing (AM). The methodology combines relies on two key innovations: an innovative layer-by-layer (LbL) powder coating technique and a custom-designed AM strategy enabling spatially selective activation of material properties.
The LbL process allows for depositing multiple functional layers, each with controlled thickness and tailored magnetic, thermal, or electrical properties, onto base magnetic powders. These coatings are then selectively activated using during AM by locally adjusting targeted key parameters such as beam power and beam scan. This unique integration of engineered powder design and locally adaptable AM processing enables the fabrication of magnetic components with spatially resolved application-specific functionalities from a single feedstock. For example, E-MOTIONS innovations enable the production of a stator core with one zone optimised for high magnetic permeability to enhance flux 3D path and another zone engineered for superior thermal stability to manage localised heating and robustness, achieving both in a single, monolithic component without post-processing or assembly. By bridging advanced materials design, multifunctional powder engineering, and intelligent AM process control, E-MOTIONS establishes a new paradigm shift in magnetic system manufacturing. This approach opens new horizons for highly efficient, compact, and customisable components across sectors such as e-mobility, renewable energy, robotics and industrial automation, positioning Europe at the forefront of next-generation functional magnetic materials.
People involved
- Emir Poskovic (Principal Investigator)
- Manuela Galati (Responsabile Scientifico di Struttura)
- Lorenza Maddalena (Responsabile Scientifico di Struttura)
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ERC sectors
Sustainable Development Goals
Budget
| Total cost: | € 90,000.00 |
|---|---|
| Total contribution: | € 90,000.00 |
| PoliTo total cost: | € 90,000.00 |
| PoliTo contribution: | € 90,000.00 |