The Korea Institute of Machinery & Materials (KIMM) has developed an innovative magnetic 3D printing technology that enables the production of high-performance motors without the use of molds. This process, which utilizes specially designed 3D printing equipment and customized material designs, opens up new possibilities in motor manufacturing. The performance evaluation of electric motors produced using this method has been successfully completed, highlighting the potential of the technology.
A team led by Dr. Taeho Ha from the 3D Printing Department at the Research Institute of Autonomous Manufacturing collaborated with the Korea Institute of Materials Science and Gachon University to develop this technology. It encompasses all key steps, from material development to process and equipment optimization. The goal was to create motors with higher performance and efficiency within the same size constraints.
At the core of the innovation is a 3D printing process that optimizes the magnetic properties of materials. This eliminates the limitations of traditional manufacturing methods, which are often constrained by molds and two-dimensional designs. The technology is particularly well-suited for axial flux motors, which are used in compact applications such as robotics, electric mobility, and medical devices, where high torque and power requirements must be met. A prototype 500-watt motor with a power density exceeding 2.0 kW/L was successfully fabricated.
Conventional motors, which rely on laminated steel or powder-based processes, face challenges such as high costs, material waste, and environmental impacts. The magnetic 3D printing technology overcomes these issues, promising cost reductions and greater design flexibility.
Dr. Taeho Ha remarked, “This magnetic 3D printing technology represents an innovative leap beyond traditional manufacturing methods, unlocking new possibilities for next-generation high-performance motors. Moving forward, we plan to expand into advanced industrial fields by integrating this with 3D printing technologies for high-functional materials.”
The research was supported by KIMM’s Basic Research Program and the Nano & Materials Technology Development Program of the National Research Foundation of Korea. These developments demonstrate how 3D printing can drive a paradigm shift toward more flexible and sustainable manufacturing methods in the long term.
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