Abstract
Additive manufacturing technology carries its potential to develop high-performance electrical machines enabling direct printing of complex shapes and incorporating the complex sequence of feedstock materials in a single build to optimize the demanding physical parameters such as low weight, cost, energy loss, and high mechanical strength and corrosion resistance. We printed Fe-3%Si stator core using selective laser melting and machined it down to thin laminates to assemble a prototype brushless permanent magnet electric motor. The magnetic and electrical properties of the thin heat-treated laminates and back emf of the electrical motors are studied. The thin laminates exhibit maximum relative permeability of 7494 with an approximate 0.8 T applied field and core-loss of 0.473 watts/lb at 60 Hz. We will report in detail about the magnetic and mechanical properties of Fe3Si soft magnets and their influence on the electrical motor. The designed machine is analyzed using finite element analysis and compared with measured electrical parameters. **
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