Stauber S, Wirthmann F, Baader M, Franke J, Risch F (2025)
Publication Type: Conference contribution
Publication year: 2025
Publisher: Institute of Electrical and Electronics Engineers Inc.
Conference Proceedings Title: EDPE 2025 - 37th International Conference on Electrical Drives and Power Electronics and 12th Joint Croatia-Slovakia Conference
Event location: Dubrovnik, HRV
ISBN: 9781665457873
DOI: 10.1109/EDPE66853.2025.11224192
The electrification of vehicles is advancing rapidly across various branches of the mobility industry, ranging from passenger cars and commercial vehicles to special-purpose machinery and aviation applications. For small series and prototypes, the production of electric drives is often associated with high manufacturing costs, lengthy production cycles, and extensive manual process steps. Tool-free processes, such as additive manufacturing, are therefore ideally suited to address low production volumes and to offer the flexibility required for the production of the various component variants. In addition, additive manufacturing not only enables the realization of complex geometries, but also the integration of multiple functions into single components. Critical components in highperformance electric drives are the electric conductors, which are typically made from copper due to its advantageous material properties, such as electrical conductivity. The market for additive manufacturing of copper is dynamic and there are various cutting-edge production technologies available, each with its unique strengths and trade-offs. This paper provides a systematic and comprehensive comparison of state-of-the-art additive manufacturing technologies for the production of copper conductors used in electric drives. Technologies discussed include laser powder bed fusion (LPBF), wire arc additive manufacturing (WAAM), directed energy deposition (DED), and other processes. The evaluation is based on criteria such as the resulting material properties, achievable resolution, and related process characteristics. The results are presented in a structured manner to support the selection of the most suitable additive manufacturing processes for the production of copper conductors used in electric drives. Furthermore, the results can also be transferred to other applications with components made from copper.
APA:
Stauber, S., Wirthmann, F., Baader, M., Franke, J., & Risch, F. (2025). Evaluation of Additive Manufacturing Technologies for Copper Conductors in Electric Drives. In Zeljko Jakopovic, Jadranko Matusko (Eds.), EDPE 2025 - 37th International Conference on Electrical Drives and Power Electronics and 12th Joint Croatia-Slovakia Conference. Dubrovnik, HRV: Institute of Electrical and Electronics Engineers Inc..
MLA:
Stauber, Simon, et al. "Evaluation of Additive Manufacturing Technologies for Copper Conductors in Electric Drives." Proceedings of the 37th International Conference on Electrical Drives and Power Electronics, EDPE 2025, Dubrovnik, HRV Ed. Zeljko Jakopovic, Jadranko Matusko, Institute of Electrical and Electronics Engineers Inc., 2025.
BibTeX: Download