KIMM Develops Revolutionary Magnetic Additive Manufacturing Technology for High-Performance Motors

Innovative Manufacturing for Next-Generation Motors
The Korea Institute of Machinery & Materials (KIMM) in South Korea has pioneered a magnetic Additive Manufacturing (AM) technology designed to produce high-performance motors without the need for traditional molds. This breakthrough offers significant advantages in industries such as robotics, Electric Vehicles (EVs), and mobility solutions, where compact, high-output motors are essential. The technology enables the creation of complex motor designs that are lighter, more efficient, and capable of higher performance than those produced by traditional manufacturing methods.

Application to Axial Flux Motors: High Torque and Compact Design
KIMM has specifically applied this magnetic AM technology to develop axial flux motors. These motors, known for their efficiency in high-torque applications and space-constrained environments, are particularly suitable for EVs and robotics. By using this new technology, KIMM has successfully created a 500W-class motor with a remarkable output density of over 2.0 kW/L, which is significantly higher than conventional motors of similar size. This output density demonstrates the potential of AM to revolutionize motor performance in areas where size and power density are crucial, such as in mobility solutions.

Collaborative Research for Technological Advancement
The breakthrough in magnetic AM was made possible by the collaborative efforts of Dr. Taeho Ha’s team at KIMM, Dr. Taehun Kim’s team from the Korea Institute of Materials Science, and Professor Wonho Kim’s team at Gachon University. The collaboration focused on overcoming key challenges in motor manufacturing, particularly in the areas of design, materials, and process optimization. Together, they have developed a comprehensive solution to enable the production of high-performance motors with superior output capabilities and efficiency.

Benefits Over Traditional Manufacturing Methods
Traditional motor manufacturing processes, such as electrical steel lamination and powder forming, rely heavily on molds and are constrained by limited design flexibility. These methods also contribute to material waste and higher production costs. In contrast, the new magnetic AM technology developed by KIMM eliminates the need for molds, enabling greater design freedom, reduced material waste, and a more cost-effective manufacturing process. By simplifying the production process, the technology makes it possible to manufacture high-performance motors in smaller quantities and with more variety, addressing the growing demand for customizable motor solutions across industries.

Future Implications and Expanding Applications
This magnetic AM technology not only offers improvements in motor performance but also sets the stage for future advancements in manufacturing. The technology’s ability to produce high-performance motors with less waste and greater efficiency could lead to further innovation in industries that rely on compact, powerful motor systems, such as electric transportation, robotics, and renewable energy. Dr. Taeho Ha emphasized that this technological leap represents a shift in motor manufacturing and is expected to unlock new possibilities in next-generation industrial fields. KIMM plans to continue advancing this technology by integrating it with 3D printing for high-functional materials.

Support from National Research Initiatives
The development of this technology was supported by KIMM’s Basic Research Program for Additive Manufacturing equipment and the Nano & Materials Technology Development Program from the National Research Foundation of Korea. These initiatives underscore the importance of the project and its potential to drive innovation in advanced manufacturing technologies.