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<p>The advancement of additive manufacturing (AM) has opened new possibilities in the design and optimization of electric motors, enabling enhanced performance through customized magnetic properties and geometries. This paper presents an innovative approach to designing and implementing 2-pole 12 W 2400 rpm permanent magnet DC (PMDC) motor using additively manufactured permanent magnets (AM-PMs). This paper aims to achieve reduced magnetic losses and improved power density compared to conventionally manufactured magnets by utilizing AM techniques. The air gap flux density is optimized, resulting in a more efficient magnetic field distribution. Additionally, cogging torque has been reduced by approximately 40%, leading to smoother operation and minimized torque ripple. Furthermore, an increase in flux linkage enhances the overall electromagnetic performance, improving power output and efficiency. These improvements contribute to better motor performance, reduced vibrations, and enhanced reliability. Finite element analysis (FEA) simulations in ANSYS Maxwell confirm theoretical improvements by demonstrating higher flux concentration, reduced cogging torque, and air gap flux density. Moreover, the experimental test shows that AM-PMs make them suitable for high-performance electric motor applications. Comparing the nominal design with the AM design, both simulation and experimental results confirm that the full-load efficiency of the PMDC motor has improved from approximately 73% to 78% with detailed electromagnetic loss analysis. The findings indicate that AM-based magnet fabrication can revolutionize PMDC motor design, offering a cost-effective, scalable, and high-efficiency solution for next-generation electric drive systems.</p>

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Enhancing PMDC motor performance through additive manufacturing: design, fabrication, and performance analysis

  • 期刊论文

  • 发表日期：

    2025年12月3日

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  • Burak Esenboğa,
  • Abdurrahman Yavuzdeğer,
  • Ömer Can Tolun,
  • Fırat Ekinci

摘要

The advancement of additive manufacturing (AM) has opened new possibilities in the design and optimization of electric motors, enabling enhanced performance through customized magnetic properties and geometries. This paper presents an innovative approach to designing and implementing 2-pole 12 W 2400 rpm permanent magnet DC (PMDC) motor using additively manufactured permanent magnets (AM-PMs). This paper aims to achieve reduced magnetic losses and improved power density compared to conventionally manufactured magnets by utilizing AM techniques. The air gap flux density is optimized, resulting in a more efficient magnetic field distribution. Additionally, cogging torque has been reduced by approximately 40%, leading to smoother operation and minimized torque ripple. Furthermore, an increase in flux linkage enhances the overall electromagnetic performance, improving power output and efficiency. These improvements contribute to better motor performance, reduced vibrations, and enhanced reliability. Finite element analysis (FEA) simulations in ANSYS Maxwell confirm theoretical improvements by demonstrating higher flux concentration, reduced cogging torque, and air gap flux density. Moreover, the experimental test shows that AM-PMs make them suitable for high-performance electric motor applications. Comparing the nominal design with the AM design, both simulation and experimental results confirm that the full-load efficiency of the PMDC motor has improved from approximately 73% to 78% with detailed electromagnetic loss analysis. The findings indicate that AM-based magnet fabrication can revolutionize PMDC motor design, offering a cost-effective, scalable, and high-efficiency solution for next-generation electric drive systems.