HOW WE DO IT
3D INDUCTOR MANUFACTURING METHOD
The original and unique additive manufacturing coils based on Electron Beam Melting (EBM) made of pure copper.
Such technology commonly called “3D printing” simplifies and shortens the manufacturing process with direct manufacturing from CAD design with extreme density material. This technology is deployed in other industries such as aerospace and orthopaedic implants using titanium or Cobalt-Chrome materials where achieving the material properties is crucial.
The method is composed of several phases where the objective is to guarantee the inductor quality using 3D printing technology.
When the coil has been printed previously
The process is the same except the first phase that is not necessary because it is registered from the first application. Repeat coils can be reproduced quickly and with total accuracy.
The EBM Printing process
1
The coils are built up, layer-by-layer of metal powder, melted by a powerful electron beam. Each layer is melted to the exact geometry as defined by a 3D CAD model.
2
First a thin layer of metal powder particles is deposited in the working plate and then flattened. Powder is preheated to very high temperatures.
3
In the next step the electron beam is focused and controlled in the X-Y dimension by means of an electromagnetic coil in order to selectively melt the powder particles on top of the working plate.
4
The result is the creation of the desired section and simultaneously it is fused to the previous layer. A new layer is then created, and the steps are repeated up to the completion of coil .
Optionally the coil surface could be improved with sand shot blasting, classical manual finishing or through mechanical post-processes.
Working plate with pure copper 3D printed coils
Scheme of main blocks in EBM machine
Technical advantages
In comparison of other 3D printing techniques.
Material purity
No additional elements.
Faster fabrication
The high energy density used for melting, allows less time to melt each layer, making this method faster than other additive fabrication methods..
Guaranteed no porosity or oxide
in the manufacture thanks to the vacuum atmosphere.
Very high mechanical performance
Melted material is preheated giving extremely mechanical properties compared with other additive technologies.
Reduction of internal stress
The uniform thermal environment ensures printed inductors are free of internal stresses.
Reactive materials
High chemical purity means greater conductive performances.
65% energy conversion efficiency
Most of the energy used by the beam is absorbed by copper. Greater efficiency than other 3D printing technologies.
Recycling
Most of the metal powder particles (97%) that has not been used in the process can be recovered and used again.
Customer cases
In-field coils examples
Full adaptation to complex parts and extreme long service life, up to 400% more in some cases, are the main benefits.
EXTREME LONG SERVICE LIFE
CRANKSHAFTS
Journals
HUB & SPINDLE
Inner Race
Outer Race
DRIVELINE
Ball Outer race
Inner Race
Stem
SLEWING BEARINGS
Teeth
Tracks
GENERIC
Complex geometry
