Axial flux motor: design optimization by means of copper additive manufacturing

This thesis presents the design and analysis of a yokeless axial flux electric motor, leveraging the unique advantages of pure copper additive manufacturing. By exploiting the enhanced geometric freedom and improved material utilization offered by advanced 3D printing technologies, a novel motor architecture is developed with a strong focus on performance optimization and loss reduction. The absence of a central magnetic yoke not only simplifies the magnetic path but also enables a more compact and lightweight configuration. Detailed electromagnetic modeling, thermal analysis, and analytical loss evaluations are conducted to validate the proposed design. The outcome highlights the transformative potential of additive manufacturing in electric motor development, enabling breakthroughs in both performance and design flexibility.