Additively manufactured electric machine conductors with integrated end turn heat exchangers

James Pecotich, David Klink, Greg Heins, Behrooz Bahrani

Research output: Chapter in Book/Report/Conference proceedingConference PaperResearchpeer-review

4 Citations (Scopus)


Conductors within a loaded electric machine commonly induce the highest loss. Numerous cooling solutions exist for high-power density electric machine conductors with external water jackets being the most common. The inherent disadvantage of water jacket cooling is the thermal resistance between the conductor and the cooling medium, which reduces the maximum cooling capacity, regardless of the jacket design. This restriction commonly leads designers to implement solutions such as end-turn cooling. The advances in additive manufacturing have unlocked new potential for conductor end-turn cooling. This paper investigates an additively-manufactured conductor with an integrated end-turn heat exchanger. The conductor is based around a Formula Student in-hub motor. This concept utilizes air-cooling and demonstrates a steady-state current density of 11 A/mm2 for a AlSi10Mg end-turn heat-exchanger conductor, without the added mass and complexity of liquid cooling solutions. If copper is used instead of AlSi10Mg, this value increases to approximately 22 A/mm2.

Original languageEnglish
Title of host publication2022 International Conference on Electrical Machines (ICEM 2022)
EditorsAntonio Luque, Vicente Biot Monterde
Place of PublicationPiscataway NJ USA
PublisherIEEE, Institute of Electrical and Electronics Engineers
Number of pages7
ISBN (Electronic)9781665414326
ISBN (Print)9781665414333
Publication statusPublished - 2022
EventInternational Conference on Electrical Machines 2022 - Valencia, Spain
Duration: 5 Sept 20228 Sept 2022 (Proceedings) (Website)

Publication series

Name2022 International Conference on Electrical Machines, ICEM 2022
PublisherIEEE, Institute of Electrical and Electronics Engineers
ISSN (Print)2381-4802


ConferenceInternational Conference on Electrical Machines 2022
Abbreviated titleICEM 2022
Internet address


  • Additive Manufacturing
  • Conductors
  • Electric Machines
  • Energy Dissipation
  • Motors
  • Stators
  • Thermal Management

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