# An Additively Manufactured Fe-3 Si Stator for a High-Performance Electrical Motor
## 2 Experimental Methods and Printed Material Characterization
### Motor Assembly  
The printed stator and hollow cylinders were cut (via EDM) into thin laminates and rings, as shown in Figure 2a,b. The thickness of each sliced laminate was 1.4 mm. This larger thickness is due to avoid warping of the sliced part. The AM laminate process differs from the conventional process in that a bulk is formed and then cut instead of the material being rolled thin and then punched. Internal stresses are unfortunately inherent within the bulk, and the removal of thickness eliminates the structural resistance to said stress, liberating them to do as they will, warping and deforming the material. The laminates were bonded using a mixture of Dolph's CC-1105 resin and 30 \(\upmu\)m glass spheres. The spheres were used to ensure isolation from one laminate to the next to reduce the eddy current loss. To electrically isolate the surface of the laminates from the housing, well-fitted, 3D-printed nylon laminates were attached on the top and bottom. Additionally, each winding slot was further insulated using Nomex Kapton tape. Three-phase coils were wound using 26 American Wire Gauge round Cu magnet wire. Each phase consisted of 16 eight-turn coils in series using eight parallel strands of wire, which resulted in 128 wires in each slot. The wound coils were positioned into the core slots and held in place using a top stick made from a NOMEX-KAPTON-NOMEX three-ply laminate with polyimide film. Tail ends of the phase leads were soldered to a single neutral connection, forming a Wye configuration. The end windings were compressed with a custom tool so that the stator would fit into the motor housing envelope, as shown in Figure 2c. Finally, the stator windings were vacuum-impregnated with CC-1105 varnish resin to consolidate the insulation to prepare the stator for motor assembly. The motor was controlled using a Smartsyn brushless resolver. The permanent magnets utilized for this motor were made via BAAM 3D printing [25]. These magnets are approximately 63 volume percent isotropic NdFeB, with the rest being polypropylene sulfide (PPS) acting as the filler polymer. The manufacturing process for these magnets is nearly identical to the one described in \"Additive Manufacturing of Isotropic NdFeB PPS Bonded permanent Magnets\" by [PERSON] et al. [24]. In short, BAAM is a large-scale variant of the common FDM AM process, with the notable exception of using a hooper for feedstock in pellet form, and the machine compresses the feedstock pellets into filament form for printing, layer upon layer. A filler polymer is needed as NdFeB by itself does not possess enough viscosity to work in BAAM. The inclusion of the filler polymer makes BAAM composite magnets and can introduce the polymer's properties into the magnet, such as the high mechanical strength of the PPS. The remanence, coercivity, and energy product of the printed magnets were B\({}_{\text{r}}\) > 5 kg, H\({}_{\text{C}}\) > 11 kOe, and BH\({}_{\text{(max)}}\) > 5.7 MOe. In the case of the rotor assembly, a single-pole BAAM-printed NdFeB-PPS magnet [24] was installed in the Arnold magnetic benchmark rotor housing and magnetized, and the final rotor was assembled, as shown in Figure 2d,e. Figure 2f shows the stator in the housing, and Figure 2g,h show the final fabricated motor.