Electrical Insulation

Advanced Electrical Insulation for 3D Printed Windings: Enhancing Performance and Reliability

At USP3D, we recognize that high-performance 3D printed windings for electric motors demand advanced insulation solutions. Our proprietary insulation technology is designed to deliver superior electrical, thermal, and mechanical properties, crucial for applications with high power density.

Key Advantages of Our Insulation Technology:

1. Precise Film Thickness Control: Our process allows for film thickness ranging from 25 to 200 µm, offering the flexibility to optimize insulation performance based on the specific requirements of each application.

2. Broad Material and Thermal Class Range: We provide access to a diverse selection of insulation materials, extending thermal capabilities up to 260°C, surpassing typical catalogue options. This ensures reliability in high-temperature environments.

3. Automated and Scalable Application Process: Our insulation process is highly automated, ensuring consistency, scalability, and efficiency. This results in a more streamlined production workflow, reducing manufacturing time and improving overall quality.

4. Adaptability to Complex Geometries: Our insulation method offers enhanced flexibility and uniformity, allowing us to cover complex coil geometries.

5. Direct Application to Final Coil: By applying insulation directly onto the final bare coil, we eliminate the need for post-processing or mechanical tooling. This minimizes the risk of mechanical stress on the winding, particularly at the end windings, improving long-term durability.

6. High Partial Discharge Inception Voltage (PDIV): The insulation we use significantly enhances the partial discharge inception voltage, increasing the overall electrical stability of the motor and extending its operational lifespan.

With these advancements, our insulation technology not only enhances the electrical performance of 3D printed windings but also contributes to higher reliability, efficiency, and cost-effectiveness. This makes it an essential component in pushing the boundaries of electric motor innovation.

Additional Benefits of Our Insulation Technology:

1. Tight Tolerances and Void-Free Windings: By achieving precise insulation thickness and tight tolerances, we ensure there is no air between winding turns. This air-free configuration significantly enhances the electrical and thermal performance of the windings, eliminating the need for impregnation.

2. Improved Fill Factor: Our insulation process increases the fill factor by maximizing the amount of conductive material within the available space. This leads to better power density and improved motor efficiency.

3. Superior Thermal Performance: The absence of air gaps enhances heat dissipation, ensuring that the windings operate at optimal temperatures even under high loads. This contributes to greater overall motor efficiency and reliability.

4. Zero Clearance Between Turns: With zero clearance between winding turns, our solution enables higher power output and improved energy efficiency. This results in a more compact and efficient motor design, ideal for high-performance applications.

By eliminating the impregnation process and optimizing the winding structure, our insulation technology offers a streamlined, high-performance solution for modern electric motors. This breakthrough not only reduces production complexity but also contributes to superior motor performance and longevity.