STUDY OF THE PROSPECTS OF USING 3D PRINTED METAL-CERAMIC ALLOYS IN ELECTRIC MOTORS
Ibraim A.S. Absadykov B.N. Kalmaganbetov S.A. Absadykov D.B.
2025National Academy of Sciences of the Republic of Kazakhstan
News of the National Academy of Sciences of the Republic of Kazakhstan, Series of Geology and Technical Sciences
2025#2025Issue 355 - 68 pp.
Relevance: The global transition to electrification of transportation, aerospace, and industry is increasing the demand for efficient, lightweight, and heat-resistant electric motor systems. Advances in additive manufacturing (AM), especially in the field of metal-ceramic composites, are a breakthrough in the field of electric motor modernization. This study examines overcoming the limitations associated with polymer and aluminum structures by integrating metal-ceramic composites into brushless DC motors (BLDC). Objective: To evaluate the practical feasibility, thermal efficiency, and design advantages of 3D-printed metal-ceramic composites for DC motors under standard thermal and electromagnetic conditions. Methods: Three 500-watt motor designs were modeled in Autodesk Fusion 360: a polymer-based motor (PETG, ABS, PEEK via FDM), an engine with a metal-ceramic body based on ALO₃ and ceramic bearings, and a conventional aluminum motor. Each design provided 240 watts of power on 12 windings. Thermal loads, bearing friction, and magnetic fields were evaluated in the simulation. AM methods included SLS, DML, and SLM. Results: The temperature in the plastic engines reached 285.7 °C, in the aluminum engines-117.5 °C, and in the metal-ceramic version-89.9 °C. The composite engine has a thinner body and integrated cooling. Discussion and conclusions: The AM metal-ceramic coating provides excellent thermal control, structural strength and design freedom-an ideal solution for next-generation electric drive systems, despite the higher cost and complexity of processing.
3D printing , additive technologies , BLDC , composite materials , electric motor , energy efficiency , metal ceramics
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Satbayev University, Almaty, Kazakhstan
Astana IT University, Astana, Kazakhstan
Satbayev University
Astana IT University
10 лет помогаем публиковать статьи Международный издатель
Книга Публикация научной статьи Волощук 2026 Book Publication of a scientific article 2026