Research Project AddReMo Investigates 3D Printing for More Efficient Electric Motors

Despite relaxed regulations regarding the phase-out of internal combustion engines, the electrification of transport remains a key component in reducing CO₂ emissions. Against this backdrop, a new research project is working on the further development of electric drive systems based on additive manufacturing. Led by Paderborn University , the initiative known as AddReMo is investigating how electric motors can be manufactured more efficiently, resource-efficiently, and flexibly using 3D printing.

The project has a total volume of around €11.5 million and is funded over three years by the Federal Ministry for Economic Affairs and Energy. In addition to academic institutions, industry partners such as Mercedes-Benz AG and Siemens AG are involved. Research and innovation management is coordinated by TÜV Rheinland. The aim is to systematically make additive manufacturing processes usable for the production of key motor components.

The focus is on three different 3D printing processes, which are specifically applied to optimize geometry, material usage, and functionality.

“Our goal is to develop innovative technologies for the production of electric drive systems that contribute to sustainable mobility and a significant reduction in CO₂ emissions,” says Prof. Dr.-Ing. Balázs Magyar, Head of Design and Drive Technology at Paderborn University. Together with Siemens AG, the chair forms the consortium leadership of the research project. The focus is on research into and application of additive manufacturing processes for the production of electric motors. “We are using three different processes[2] to leverage design freedom and optimize material usage. The emphasis is on further development with regard to process stability, the processing of novel high-performance materials in mono- and multi-material applications, simulation-supported design, and AI-based quality assurance,” Prof. Magyar continues.

For industrial application, the participating companies are developing demonstrators that will be technically and economically evaluated and integrated into existing drive systems.

“By comparing the manufacturing processes, the mechanical, thermal, and magnetic properties of the electric motors are analyzed and validated under real conditions through simulation and experimental testing. The aim is to carry out both a technical and an economic-ecological evaluation of the processes and the electric motors in order to achieve series-ready production,” explains Prof. Dr.-Ing. Mirko Schaper, Head of the Chair of Materials Science at Paderborn University and Dean of the Faculty of Mechanical Engineering.

The results of AddReMo are intended not only to address e-mobility, but also to provide impetus for stationary electric motors. In this way, the project aims at broader industrial application of additive manufacturing in the drive technology sector.