The art of successful design of electrical machines comes with many challenges in the mass, size, energy efficiency, and thermal management. At the end, a successful design should have an optimal balance between the performance and the manufacturability. This work highlights the importance of additive manufacturing (AM) for the design and fabrication of unconventional motors with higher power density.

The technology of 3D printing offers much higher flexibility in dimensions as well as in material engineering. The primary focus of this thesis centers on three key aspects of electrical machines: magnetic materials, windings, and thermal management. These three contributions can improve future electric machines in terms of efficiency and power density.

Using AM technology, a series of novel coils and cores is designed and prototyped for high-power density electrical machines. The 3D coil designs combine higher performance and easier manufacturability. Moreover, a new thermal management concept is introduced featuring lower weight and better thermal behavior.

Overall, the proposed approaches highlight the unique capabilities of AM to overcome traditional manufacturability challenges and enable new design possibilities that contribute to the scalability, reliability, and effectiveness of electrical machines, making them more accessible for various applications