Systems and methods for additive manufacturing

Abstract

An additive manufacturing system may include a workbench, a support structure, a first powder dispenser, and a second powder dispenser. The workbench can rotate about a first rotation axis. The support structure can be mounted to move relative to the workbench. The first powder dispenser can be mounted to the support structure and can extend radially across the workbench. The first powder dispenser includes a first outlet vertically arranged above the workbench. The second powder dispenser can be mounted to the support structure and can extend radially across the workbench. The second powder dispenser includes a second outlet vertically arranged above the workbench. The workbench can rotate about the first rotation axis relative to the support structure and the first powder dispenser and the second powder dispenser. The first powder dispenser and the second powder dispenser can move together with the support structure relative to the workbench in a direction parallel to the first rotation axis.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Patent Application No. 16 / 053,080, filed on August 2, 2018, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] The present disclosure relates to systems and methods for additive manufacturing, and in particular for additive manufacturing of stators. Background Art

[0004] This section provides background information related to the present disclosure which is not necessarily prior art.

[0005] A stator for an electric motor may include a stack of laminations having alternating layers of magnetically susceptible layers and insulating layers. The insulating layers reduce eddy current losses in the stator. Reducing the thickness of the layers can further reduce eddy current losses. However, there are limits to how thin the layers can be made by conventional methods. If the layers are made too thin, conventional manufacturing processes become unreliable and the layers become too fragile to handle and process. The present disclosure provides a system and method for manufacturing a laminated stator (or other laminated component) that allows each individual layer to be formed very thin while also allowing various features to be formed on or in the stator. Summary of the invention

[0006] This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

[0007] In one form, the present disclosure provides a system that may include a workbench, a support structure, a first powder dispenser, and a second powder dispenser. The workbench may be rotatable about a first axis of rotation. The support structure may be mounted to move relative to the workbench. The first powder dispenser may be mounted to the support structure and may extend radially across the workbench. The first powder dispenser may include a first outlet vertically disposed above the workbench. The second powder dispenser may be mounted to the support structure and may extend radially across the workbench. The second powder dispenser may include a second outlet vertically disposed above the workbench. The workbench may be rotatable about the first axis of rotation relative to the support structure and the first and second powder dispensers. The first and second powder dispensers may be movable relative to the workbench in a direction parallel to the first axis of rotation together with the support structure.

[0008] In some configurations, the system may include an adhesive dispenser mounted to the support structure and extending radially across the workbench, the adhesive dispenser having a third outlet disposed vertically above the workbench. The adhesive dispenser may be circumferentially spaced from the first powder dispenser and the second powder dispenser. The adhesive dispenser may be movable with the support structure relative to the workbench in a direction parallel to the first axis of rotation.

[0009] In some configurations, the system of one or both of the above paragraphs may include a compaction roller mounted to the support structure and disposed vertically above the work table. The compaction roller may be rotatable relative to the support structure and the work table about a second rotation axis, the second rotation axis being angled relative to the first rotation axis.

[0010] In some configurations of the system of one or more of the foregoing paragraphs, the compaction roller includes a frusto-conical rolling surface.

[0011] In some configurations of the system of one or more of the above paragraphs, the compaction roller is disposed circumferentially between the second powder distributor and the binder distributor.

[0012] In some configurations, the system of one or more of the above paragraphs may include a curing element attached to the support structure and extending radially across the workbench. The curing element may be vertically disposed above the workbench. The binder dispenser may be circumferentially disposed between the curing element and the second powder dispenser.

[0013] In some configurations, the system of one or more of the above paragraphs may include a third powder dispenser mounted to the support structure and extending radially across the workbench. The third powder dispenser may include a fourth outlet disposed vertically above the workbench. The third powder dispenser may be circumferentially spaced from the first powder dispenser and the second powder dispenser. The third powder dispenser may be movable with the support structure relative to the workbench in a direction parallel to the first axis of rotation.

[0014] In some configurations of the systems of one or more of the above paragraphs, the first powder dispenser and the second powder dispenser are rotationally fixed relative to the first rotation axis.

[0015] In another form, the present disclosure provides a system that may include a workbench, a first powder dispenser, a second powder dispenser, and a binder dispenser. The workbench may be rotatable about a first rotation axis. The first powder dispenser may extend radially across the workbench. The first powder dispenser may include a first outlet disposed vertically above the workbench. The second powder dispenser may extend radially across the workbench. The second powder dispenser may include a second outlet disposed vertically above the workbench. The binder dispenser may extend radially across the workbench. The binder dispenser may include a third outlet disposed vertically above the workbench. The binder dispenser may be circumferentially spaced apart from the first powder dispenser and the second powder dispenser. The workbench may be rotatable about the first rotation axis relative to the first powder dispenser and the second powder dispenser and the binder dispenser. The first powder dispenser and the second powder dispenser and the binder dispenser may be movable relative to the workbench in a direction parallel to the first rotation axis. The first powder dispenser and the second powder dispenser and the binder dispenser may be rotationally fixed to each other.

[0016] In some configurations, the system of one or more of the above paragraphs may include a support structure that supports the first powder dispenser, the second powder dispenser, and the adhesive dispenser, and is capable of moving together with the first powder dispenser, the second powder dispenser, and the adhesive dispenser in a direction parallel to the first rotation axis.

[0017] In some configurations, the system of one or more of the above paragraphs may include a compaction roller mounted to the support structure and extending radially from the support structure across the worktable. The compaction roller may be disposed vertically above the worktable. The compaction roller may be rotatable relative to the support structure and the worktable about a second rotation axis, the second rotation axis being angled relative to the first rotation axis.

[0018] In some configurations of the systems of one or more of the above paragraphs, the second axis of rotation is disposed at a non-perpendicular angle relative to the first axis of rotation.

[0019] In some configurations of the system of one or more of the above paragraphs, the support structure is disposed radially inwardly relative to an inner diameter of the table.The first and second powder dispensers, the binder dispenser, and the compacting roller may extend radially outwardly from the support structure.

[0020] In some configurations of the system of one or more of the foregoing paragraphs, the compaction roller includes a frusto-conical rolling surface.

[0021] In some configurations of the system of one or more of the above paragraphs, the compaction roller is disposed circumferentially between the second powder distributor and the binder distributor.

[0022] In some configurations, the system of one or more of the above paragraphs may include a curing element extending radially across the workbench. The curing element may be vertically disposed above the workbench. The binder dispenser may be circumferentially disposed between the curing element and the second powder dispenser.

[0023] In some configurations, the system of one or more of the above paragraphs may include a third powder dispenser extending radially across the workbench. The third powder dispenser may include a fourth outlet vertically disposed above the workbench. The third powder dispenser may be circumferentially spaced apart from the first powder dispenser, the second powder dispenser, and the binder dispenser. The third powder dispenser may be movable relative to the workbench in a direction parallel to the first axis of rotation together with the first powder dispenser, the second powder dispenser, and the binder dispenser.

[0024] In yet another form, the present disclosure provides a manufacturing method which may include: rotating a workbench about a first rotation axis; dispensing powdered magnetically sensitive material onto the workbench while the workbench rotates; dispensing powdered insulating material onto the workbench while the workbench rotates; dispensing adhesive material onto the workbench while the workbench rotates; forming a plurality of first layers of the magnetically sensitive material on the workbench; and forming a plurality of second layers of the insulating material on the workbench, wherein each of the second layers is axially disposed between adjacent first layers.

[0025] In some configurations, the method may include removing the first layer and the second layer from the stage and then heating the first layer and the second layer in a furnace.

[0026] In some configurations of the method of one or more of the above paragraphs, the first layer and the second layer are discrete layers.

[0027] In some configurations of the method of one or more of the above paragraphs, the first layer and the second layer cooperate to form a single continuous helical coil.

[0028] In some configurations, the method of one or more of the above paragraphs may include: compacting the powdered magnetically sensitive material on the workbench using a compaction roller; and curing the binder material after compacting the powdered magnetically sensitive material.

[0029] In some configurations, the methods of one or more of the above paragraphs may include forming holes in the first layer and the second layer by stopping dispensing the powdered magnetically sensitive material and the powdered insulating material at a selected position radially between the inner diameter and the outer diameter of the first layer and the second layer.

[0030] In some configurations, the method of one or more of the above paragraphs may include forming a conductive path through the plurality of first layers and the plurality of second layers by dispensing a powdered conductive material at selected locations on each of the first layers and the second layers.

[0031] Further areas of applicability will become apparent from the description provided herein.The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

[0033] Figure 1 A perspective view of an additive manufacturing system and layers of a stator manufactured by the system;

[0034] Figure 2 It is a top view of the system and stator;

[0035] Figure 3 is a side view of the system and stator;

[0036] Figure 4 It is a partial exploded view of the stator;

[0037] Figure 5 For along Figure 4 A partial cross-sectional view of the stator taken along line 5-5;

[0038] Figure 6 is a partial cross-sectional view of another example stator;

[0039] Figure 7 is a schematic diagram of the stator in the furnace;

[0040] Figure 8 is a partially exploded view of an alternative stator that may be manufactured by the system; and

[0041] Fig. 9 A top view of multiple systems attached to each other via a common plate.

[0042] Corresponding reference characters indicate corresponding parts throughout the several views of the drawings. DETAILED DESCRIPTION

[0043] Example embodiments will now be described more fully with reference to the accompanying drawings.

[0044] refer to Figure 1-Figure 3 , an additive manufacturing system 10 is provided that can form a layered or laminated object, such as a stator 12 of an electric motor or a core of a transformer. The system 10 can form alternating laminations of different materials and combine alternating laminations of different materials. Figure 1-Figure 5 , the system 10 may form and bond alternating laminations of magnetically susceptible material (e.g., powdered steel) and insulating material (e.g., powdered silica and / or nylon). Thereafter, the laminated stator 12 may be melted in a furnace or a melting pot 14 ( Figure 7 ) is heated or sintered to agglomerate the powdered material.

[0045] like Figure 1-Figure 3 As shown, the system 10 may include a rotary table 16, a support column (i.e., a support structure) 18, a first powder material dispenser 20, a second powder material dispenser 22, a compacting roller 24, a binder dispenser 26, and a curing element 28. In some embodiments, the system 10 may include a third powder material dispenser 31.

[0046] The rotary table 16 may be a disk-shaped plate having an outer diameter 30 and an inner diameter 32. The inner diameter 32 defines a central hole 34. The table 16 may be mounted to a fixed base or frame (not shown). A first actuator 36 (e.g., an electric motor; Figure 3 1 and 2) can be coupled to the table 16 and can be operated to rotate the table 16 about the first rotation axis A1 relative to the support column 18, the dispenser 20, 22, 26, 31, the compaction roller 24 and the curing element 28. In the specific example shown in the figure, the first actuator 36 causes the table 16 to rotate from Figure 2 The reference frame looks at the rotation in a clockwise direction.

[0047] The support column 18 can support the distributors 20, 22, 26, 31, the compacting roller 24, and the curing element 28 above the workbench 16. The support column 18 can be mounted to a fixed base or frame (for example, the same base or frame as the workbench 16 is mounted to, or a different frame or base). The support column 18 can be arranged radially inward relative to the inner diameter 32 of the workbench 16. The support column 18 can extend vertically along the first rotation axis Al of the workbench 16. In the specific example shown in the figure, the support column 18 has a cylindrical shape. In other embodiments, the support column 18 can have any other suitable shape. Figure 3As shown schematically, a second actuator 38 (e.g., an electric motor or a hydraulic or pneumatic actuator) may be coupled to the support column 18 and may drive the support column 18 (and the dispensers 20, 22, 26, 31, the compacting roller 24, and the curing element 28 attached to the support column 18) relative to the table 16 in a direction along or parallel to the first rotation axis A1. In some configurations, the column 18 or columns 18 may be attached to a plate that is movable along the first rotation axis A1.

[0048] The first dispenser 20 and the second dispenser 22 may be fixedly attached to the support column 18 and may extend radially outward from the support column 18 and across the work table 16 (i.e., across the outer diameter 30 and the inner diameter 32 of the work table 16). The work table 16 rotates below the first dispenser 20 and the second dispenser 22. The first dispenser 20 and the second dispenser 22 may be any suitable type of powder material dispenser, such as, for example, an ultrasonic dispenser. The first dispenser 20 may dispense magnetically sensitive materials, and the second dispenser 22 may dispense insulating materials. Each of the first dispenser 20 and the second dispenser 22 may include a material reservoir 23 (which receives powder material from a powder material source) and one or more nozzles or one or more outlets 25, through which the powder material can be dispensed onto the work table 16 when the work table 16 rotates. The first dispenser 20 and the second dispenser 22 may selectively dispense a desired amount of their respective materials at any one or more radial positions along the radial range of the work table 16 between the outer diameter 30 and the inner diameter 32 of the work table 16.

[0049] The compacting roller 24 smoothes and compacts the powder material dispensed from the dispensers 20, 22 onto the table 16. The compacting roller 24 may be attached to the support column 18 and may extend radially outward from the support column 18 and across the table 16 (i.e., across the outer diameter 30 and the inner diameter 32 of the table 16). The table 16 rotates beneath the compacting roller 24. The compacting roller 24 is circumferentially spaced from the first dispenser 20 and the second dispenser 22. The bearing 40 ( Figure 1 ) can support the compaction roller 24 to rotate around the second rotation axis A2. The second rotation axis A2 is arranged at an angle (eg, a non-zero, non-perpendicular angle) relative to the first rotation axis A1 of the worktable 16.

[0050] The compacting roller 24 includes a rolling surface 42 that can rollably contact the stator 12 on the worktable 16. The rolling surface 42 may have a frustoconical shape including a first end 44 and a second end 46. The first end 44 may be disposed at or near the inner diameter 32 of the worktable 16. The second end 46 may be disposed at or near the outer diameter 30 of the worktable 16. The diameter of the rolling surface 42 increases as the rolling surface 42 extends axially from the first end 44 to the second end 46. This change in the diameter of the rolling surface 42 allows the linear velocity of the rolling surface 42 (relative to the rotating worktable 16) to be equal at each position along the axial length of the rolling surface 42. This allows the compacting roller 24 to equally compact and smooth the powder material at all radial positions between the outer diameter 30 and the inner diameter 32 of the worktable 16.

[0051] The binder dispenser 26 may be fixedly attached to the support column 18 and may extend radially outward from the support column 18 and across the table 16 (i.e., across the outer diameter 30 and the inner diameter 32 of the table 16). The table 16 rotates below the binder dispenser 26. The binder dispenser 26 may be circumferentially spaced from the compaction roller 24, such that the compaction roller 24 is circumferentially disposed between the binder dispenser 26 and the first and second dispensers 20, 22 (i.e., the powder material dispensed onto the table 16 by the first or second dispenser 20, 22 is compacted and smoothed by the compaction roller 24 before passing under the binder dispenser 26).

[0052] The binder dispenser 26 can be any suitable type of dispenser (e.g., a binder jet). The binder dispenser 26 can dispense a binder material (e.g., an adhesive) onto the powder material that has been dispensed onto the workbench 16 by the dispenser 20 and the dispenser 22 and smoothed and compacted by the compaction roller 24. The binder dispenser 26 can include a material reservoir 27 (which receives the binder material from the binder material source) and one or more nozzles or one or more outlets 29, through which the binder material can be dispensed onto the workbench 16 when the workbench 16 rotates. The binder dispenser 26 can selectively dispense a desired amount of binder material at any one or more radial positions along the radial range of the workbench 16 between the outer diameter 30 and the inner diameter 32 of the workbench 16.

[0053] The curing element 28 may extend radially across the table 16 (e.g., across the outer diameter 30 and the inner diameter 32 of the table 16). For example, the curing element 28 may be a heat source (e.g., a resistive heater with a heating coil, a flame source, a laser, a heated roller, etc.) or an ultraviolet (UV) light source. The curing element 28 may be circumferentially spaced from the binder dispenser 26 such that the binder dispenser 26 is circumferentially disposed between the compacting roller 24 and the curing element 28 (i.e., the binder material dispensed onto the table 16 by the binder dispenser 26 passes under the curing element 28). The curing element 28 may at least partially cure the binder material to bond the particles of the powder material to each other.

[0054] The third powder material dispenser 31 may be fixedly attached to the support column 18 and may extend radially outward from the support column 18 and across the workbench 16 (i.e., across the outer diameter 30 and the inner diameter 32 of the workbench 16). The workbench 16 rotates below the third dispenser 31. The third dispenser 31 may be any suitable type of powder material dispenser, such as, for example, an ultrasonic dispenser. The third dispenser 31 may dispense a conductive material (e.g., copper). The third dispenser 31 may include a material reservoir 48 (which receives powder material from a powder material source) and one or more nozzles or one or more outlets 50, through which the powder material may be dispensed onto the workbench 16 as the workbench 16 rotates. The third dispenser 31 may selectively dispense a desired amount of powder material at any one or more radial positions along the radial range of the workbench 16 between the outer diameter 30 and the inner diameter 32 of the workbench 16.

[0055] Control module 52 (in Figure 3 Schematically shown) can communicate with the first actuator 36 and the second actuator 38, the dispensers 20, 22, 26, 31, and the curing element 28. The control module 52 can control the operation of the first actuator 36 and the second actuator 38 as needed to move the workbench 16 and the support column 18, respectively. The control module 52 can also control the operation of the dispensers 20, 22, 26, 31 and the curing element 28 to dispense the desired material at the desired location, combine the desired material, and cure the desired material. The control module 52 may include a processing circuit configured to execute instructions stored on at least one non-transitory tangible computer readable medium.

[0056] In some configurations, an actuator (not shown) may drive the rotation of the compaction roller 24 (e.g., rotation about the second axis of rotation A2). The control module 52 may control the operation of such an actuator so as to drive the compaction roller 24 in a desired direction and at a desired speed. In other configurations, the compaction roller 24 may be driven by the first actuator 36 (e.g., the compaction roller 24 is coupled to the table 16 or directly to the first actuator 36 via a linkage, gears, etc.). In other configurations, friction between the rolling surface 42 of the compaction roller 24 and the stator 12 on the table 16 may drive the rotation of the compaction roller 24.

[0057] See now Figure 1-Figure 7 , a method of manufacturing a stator 12 using the system 10 will be described. As described above, the system 10 can form alternating laminations of magnetically susceptible material and insulating material and bond alternating laminations of magnetically susceptible material and insulating material. Thereafter, the laminated stator 12 can be heated in a furnace 14 ( Figure 7 ) to agglomerate the powdered material.

[0058] like Figure 4 and 5 As shown, the stator 12 manufactured using the method of the present disclosure includes a plurality of discrete first layers or laminations 60 and a plurality of discrete second layers or laminations 62. The first layers 60 may be formed of a magnetically susceptible material and the second layers 62 may be formed of an insulating material.

[0059] To form one of the first layers 60, the control module 52 may operate the first actuator 36 to rotate the work table 16, and operate the first powder material dispenser 20 to dispense powdered magnetically sensitive material onto the work table 16 while the work table 16 is rotating. The control module 52 may control the first powder material dispenser 20 to dispense an appropriate amount of powder material at a desired radial position on the work table 16 to form a desired material thickness.

[0060] As described above, when the workbench 16 rotates, after dispensing the powder material from the first powder material dispenser 20, the compacting roller 24 compacts the powder material and smoothes the powder material. Thereafter, the compacted powder material passes under the binder dispenser 26, and the binder material can be dispensed onto the compacted powder material. Thereafter, the binder material and the powder material pass under the curing element 28, which at least partially cures the binder material to bond the particles of the powder material to each other. The workbench 16 can continue to rotate, and the first powder material dispenser 20 and the binder dispenser 26 can continue to dispense in this manner to form discrete layers 60.

[0061] After a full (360 degree) rotation of the table 16, one layer 60 is formed. Then, to form a second layer 62 on the first layer 60, the above steps may be repeated using the second powder material dispenser 22 dispensing the powdered insulating material instead of the first powder material dispenser 20 dispensing the magnetically susceptible material. Another full (360 degree) rotation of the table 16 with the second powder material dispenser 22 dispensing the insulating material will form one of the second layers 62. Thereafter, the support column 18 is again moved vertically upward, and another layer 60 may be formed in the manner described above. The above steps may be repeated as many times as desired to form a desired plurality of alternating layers 60, 62.

[0062] If desired, each of the layers 60, 62 may include one or more of a variety of different features. Figure 4 As shown, each of the layers 60, 62 may include a plurality of holes 64 and / or a plurality of conductors 66. The holes 64 may be formed by stopping the dispensing of powder material from the dispensers 20, 22 only at the locations where the holes 64 need to be formed while continuing to dispense powder material from the dispensers 20, 22 around the locations where the holes 64 need to be formed. The conductors 66 may be formed by stopping the dispensing of powder material from the dispensers 20, 22 at the desired locations of the conductors 66 and instead dispensing the powdered conductive material 20 from the third dispenser 31 at the desired locations.

[0063] like Figure 1 As shown, when multiple layers 60, 62 are stacked on top of each other, selected ones of the holes 64 in the layers 60, 62 may be aligned with each other to form internal passages (e.g., coolant passages, air passages, bolt holes, etc.) in the stator 12. Similarly, for example, selected ones of the conductors 66 in the layers 60, 62 may be aligned with each other to form larger conductors (e.g., conductive paths) that may (optionally) extend through the axial length of the stator 12 and may replace conventional wires or windings.

[0064] like Figure 5 As shown, one or more of the layers 60, 62 may include one or more step features (or out-of-plane features) 68. For example, one or more of the first layers 60 may include one or more step features 68 disposed in the same plane as an adjacent second layer 62 (formed from the same material as the remainder of the first layer 60); and one or more of the second layers 62 may include one or more step features 68 disposed in the same plane as an adjacent first layer 60 (formed from the same material as the remainder of the second layer 62).

[0065] The step feature 68 in one of the first layers 60 may be formed during the formation of the adjacent second layer 62 by stopping the dispensing of powder material from the second dispenser 22 at the desired location of the step feature 68 and alternatively dispensing powder material from the first dispenser 20 at the desired location. Similarly, the step feature 68 in one of the second layers 62 may be formed during the formation of the adjacent first layer 60 by stopping the dispensing of powder material from the first dispenser 20 at the desired location of the step feature 68 and alternatively dispensing powder material from the second dispenser 22 at the desired location.

[0066] It should be appreciated that various other features may be formed in one or more of the layers 60, 62. For example, attachment features, splines, and / or other shapes may be formed in any of the layers 60, 62. Furthermore, one or more of the layers 60, 62 of a given stator 12 may have a different thickness and / or be different than the thickness of other layers 60, 62 of the same stator 12.

[0067] Figure 6 Another example of layers 60, 62 is depicted with step features or out-of-plane features 68 forming holes 64 between adjacent layers 60, 62, and with conductors 66 between adjacent layers 60, 62. It should be understood that the step features 68 may be formed in any desired shape to create desired features in the stator 12 or on the custom 12. During deposition of the material forming the out-of-plane features 68, some of the out-of-plane features 68 may be supported by unbound powder. After the material forming the out-of-plane features 68 is bonded, the unbound supporting powder may be removed.

[0068] Once the desired number of layers 60, 62 are formed using the above steps, the resulting stator 12 can be placed in a furnace 14 (in Figure 7 60, 62 to agglomerate the powdered material and bond the layers 60, 62 to each other. During the heating or sintering process, some step features or out-of-plane features 68 may be supported by, for example, a ceramic fixture or any other suitable fixture. Thereafter, the stator 12 may be removed from the fixture.

[0069] See now Figure 8, an alternative stator 112 is provided that can be formed using the above-described system 10. Similar to the stator 12, the stator 112 can have alternating layers 160, 162 (similar to the layers 60, 62, respectively). That is, each layer 160 is axially disposed between adjacent layers 162. The layers 160, 162 can be formed of the same or similar materials as the layers 60, 62, respectively, and can have the same or similar features (e.g., holes 64, conductors 66, and / or step features 68) as the layers 60, 62 of the stator 12. The stator 112 can be similar to the stator 12, except that the layers 160, 162 of the stator 112 form a single continuous spiral coil instead of the discrete layers 60, 62 of the stator 12. Each layer 160, 162 is a segment of a continuous spiral coil. The seams 164 between adjacent layers 160, 162 can be circumferentially aligned with each other or circumferentially staggered with each other.

[0070] The single continuous spiral coil of layers 160, 162 may be formed by continuously raising support posts 18 during the entire 360 ​​degree rotation of table 16 rather than raising support posts 18 in discrete steps at the end of each 360 degree rotation of table 16. As with the formation of layers 60, 62 of stator 12, layer 160 of stator 112 may be formed by dispensing powder material from first powder dispenser 20, and layer 162 of stator 112 may be formed by dispensing powder from second powder dispenser 22, as described above.

[0071] Similar to the stator 12 , once the desired number of layers 160 , 162 are formed using the steps described above, the resulting stator 112 may be heated or sintered in a furnace 14 .

[0072] See now Fig. 9 , multiple systems 10 may be operated simultaneously to form multiple stators 12 (or multiple stators 112) simultaneously. For example, the support columns 18 of each system 10 may be mounted to a common plate 70 (at Fig. 9 A single actuator (not shown) can move the plate 70 to simultaneously move all support columns 18 relative to the workbench 16.

[0073] For the purpose of illustration and description, the foregoing description of the embodiment has been provided. It is not intended to be exhaustive or to limit the disclosure. The individual elements or features of a particular embodiment are generally not limited to the particular embodiment, but are interchangeable where applicable, and can be used in the selected embodiment, even if not specifically shown or described. The individual elements or features of a particular embodiment can also be changed in many ways. This variation should not be considered as departing from the present invention, and all such modifications are intended to be included within the scope of the present disclosure.

Claims

1. A manufacturing method comprising: Rotating the workbench (16) around a first rotation axis (A1); dispensing a powdered magnetically sensitive material onto the workbench (16) as the workbench (16) rotates; dispensing a powdered insulating material onto the magnetically sensitive material while the workbench (16) rotates; dispensing adhesive material onto the magnetically sensitive material and the insulating material respectively while the workbench (16) rotates; forming a plurality of first layers of the magnetically sensitive material on the workbench (16); and forming a plurality of second layers of the insulating material on the workbench (16), wherein each second layer is axially disposed between adjacent first layers, Each of the first layer and the second layer is helical, and the first layer and the second layer cooperate to form a single continuous helical coil.

2. The method according to claim 1, further comprising: The first layer and the second layer are removed from the workbench (16) and then heated in a furnace (14).

3. The method according to claim 1, further comprising: Using a compacting roller (24) to compact the powdered magnetically sensitive material on the workbench (16); as well as The binder material is cured after the powdered magnetically sensitive material is compacted.

4. The method according to claim 1, further comprising: Apertures (64) are formed in the first and second layers by stopping dispensing of the powdered magnetically susceptible material and the powdered insulating material at selected locations radially between inner and outer diameters of the first and second layers.

5. The method according to claim 1, further comprising: Conductive paths are formed through the plurality of first layers and the plurality of second layers by dispensing a powdered conductive material at selected locations (66) on each of the first layers and the second layers.

6. A method of forming an object by additive manufacturing, the method comprising: a) Provide a rotating table; b) dispensing a powdered magnetically sensitive material onto the rotating table; c) dispensing an insulating material onto the powdered magnetically sensitive material dispensed onto the rotary table; d) compacting the powdered magnetically sensitive material and the insulating material on the rotating workbench respectively; e) dispensing an adhesive onto the magnetically sensitive material and the insulating material, respectively; and f) curing the adhesive while the rotary table rotates; wherein the above steps a) to f) are repeated to form the object, wherein the object comprises a plurality of first layers formed of the magnetically susceptible material, the plurality of first layers being interlaced with a plurality of second layers formed of the insulating material; wherein a plurality of cooling holes are formed through each of the first layers and each of the second layers, the cooling holes cooperating to form a plurality of cooling channels formed axially through the object, and Each of the first layer and the second layer is helical, and the first layer and the second layer cooperate to form a single continuous helical coil. 7 . The method of claim 6 , further comprising heating the object to sinter the powdered magnetically susceptible material in each of the first layers.

8. The method of claim 6, wherein the object is at least a portion of a stator (112) of an electric motor.

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