Additive Manufacturing for Enhanced Electric Machine Performance

Additive manufacturing (AM) has emerged as a transformative technology in electric machine (EM) design and production, addressing critical challenges in power density, thermal management, and material utilization. This review systematically examines recent advancements in 3D-printed conductive and magnetic materials, process innovations, and topology optimization strategies. Case studies in aerospace, electric vehicles, and medical robotics have demonstrated AM’s ability to reduce EM weight, improve torque density, and enable complex geometries, such as conformal cooling channels and lattice-structured rotors. Challenges, including residual-stress control, material standardization, and scalability, are critically analyzed. A roadmap for AM adoption in next-generation EMs is concluded, hybrid manufacturing and sustainable material development are emphasized.