OSLO, Norway—Electric motors are traditionally made by cutting, molding and stamping pieces of metal. As an alternative, additive manufacturing technology can increase efficiency and reduce material consumption. However, printing large motor components has proven difficult, because the parts often become too brittle and easily break.

Through an EU-funded R&D project, engineers at chemical company Elkem ASA have developed an iron-silicon powder that may make it easier to print EV motor components.

In the SOMA (lightweight solutions for e-mobility by AM for soft magnetic alloys) project, Elkem is developing materials along with partners VTT Technical Research Centre of Finland, Siemens, Stellantis and Gemmate Technologies. 

The powder is soft magnetic, meaning that it is easy to magnetize and demagnetize, which is important in electric motors. It is produced in a small-scale pilot atomizer located at the Future Materials Norwegian Catapult Centre. The powder has been used to print metal components for an electric scooter motor . 

“This is a project with potential to transform motor parts manufacturing,” says Tomi Lindroos, research team leader at VTT Materials and Manufacturing. “We have successfully created a new specialized powder with good printability based on silicon-steel (with additives). Printed components show enhanced ductility and competitive magnetic properties.”