Boost Electric Vehicle Performance Range with Lightweight, Highly Efficient Components

self flying passenger drone

The pivot towards green energy has resulted in greater adoption of eVTOLs, “flying cars,” electric helicopters, electric aircraft, and drones. Advances in the aerospace and defense industry are driving this adoption as well. All the new electric flying vehicles require highly efficient and lightweight electric motors to achieve reproducible high-performance take-off weight and flying range capabilities.

With additive manufacturing, you gain innovative design flexibility to create the lightweight, highly efficient electric motor parts (e.g., stators, rotors, heat exchangers, etc.) that enable these capabilities.

Streamline the Design and Production of Electric Engine Parts

  • interior curvature of cooling jacket

  • Achieve Integral Design

    Consolidate traditionally complex assemblies into a single 3D-printed design. Direct metal printing (DMP) gives you the significant design flexibility to combine different functional parts, allowing you to integrate thermal management geometries directly into your electric stator design and greatly reduce the complexities of conventional cooling features (e.g., heat exchangers).

  • prox dmp 320 cooling mantle

  • Lower Weight with Enhanced Functionality

    Use DMP to manufacture strong, lightweight electric motor components that maintain or enhance functional performance. Advanced DfAM can open new horizons for induction & heat transfer optimization. Since components made with DMP are lightweight, electric flying vehicles can carry more passengers or cargo without increasing costs.

More Aerospace and Defense Applications

Investment Casting Patterns for Aerospace Applications Thumbnail

Investment Casting
Metal 3D Printed DLR Fuel Injector

Propulsion
Thales Bracket Close-Up Aerospace

Lightweight Brackets
Laserform Heat Exchanger Closeup for Aerospace

Heat Exchangers
Airbus' Filter on payload detail

Radio Frequency (RF) Passive Hardware
  • imts spark logo

  • Flying into the Future with Joby Aviation

    Watch this webinar featuring Joby Aviation and learn how metal additive manufacturing fuels aerospace innovation.

    View The Webinar

  • What Can You 3D Print With Metals?

    Design, test and produce metal parts with 3D printing that are simply not possible with standard manufacturing. Create lightweight, high-strength structures and deliver new capabilities.

    Learn More

  • 3D Printing Metal Parts and Materials

    Direct Metal Printing (DMP) gives you complete design freedom to manufacture stronger parts that are light, durable and perform better than other means.

    Learn More
Learn More About Our Solutions for Electric Engine Components Applications
3D Systems DMP Factory 350 hero image

DMP Factory 350

Robust, high quality Metal AM with integrated powder management

Thales Metal Bracket LaserForm Titanium Gr. 5

LaserForm Ti Gr5 (A)

High strength, low weight, excellent biocompatibility

3D Systems ProX SLS 6100 3D Printer

ProX SLS 6100

Production-grade nylon 3D printer delivering best-in-class part quality, fast build times and automated production tools

3D Systems 3DXpert hero image

3DXpert

3D Additive Manufacturing Software

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  • Application Innovation Group

    Our team can help you solve your most difficult design and production challenges with additive manufacturing solutions. Together we’ll identify your needs, working with you to optimize your designs, prototype, validate and define a manufacturing flow.

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