Additively manufactured composite rotors optimized by AI
OptiMotor is a research project developing next-generation synchronous reluctance motors using AI-optimized rotor geometries and advanced biopolymer-based composite materials. By leveraging additive manufacturing, the project aims to create lightweight, efficient, and sustainable electric motors that eliminate the need for rare-earth magnets and copper, targeting applications in small electric vehicles, drones, and e-bikes.
Overview
The OptiMotor project is a research initiative focused on developing next-generation synchronous reluctance motors (SynRMs) to address the limitations of conventional electric motor technologies. By utilizing advanced biopolymer-based composite materials and additive manufacturing, the project aims to create electric motors that are lightweight, cost-effective, and highly efficient. This approach eliminates the reliance on expensive rare-earth permanent magnets and copper, offering a more environmentally sustainable solution for electrified transport, including small electric vehicles, drones, and e-bikes.
Technical specifications
The project employs an AI-driven multi-objective optimization workflow that integrates deep learning and computational physics models to determine optimal rotor geometry and the distribution of ferromagnetic particles. Key technical features include:
- Use of custom filaments incorporating ferromagnetic alloy particles and reinforcing fibers.
- Application of Fused Deposition Modelling (FDM) to enable complex rotor geometries that are not achievable with traditional manufacturing techniques.
- Development and characterization of biopolymer-based composite filaments to evaluate mechanical and magnetic performance.
- Focus on scalability for industrial applications through rigorous validation, testing, and manufacturability assessments.
Technology readiness level
The technology is currently in the research and development phase. The project involves collaborative efforts between academic institutions and industrial partners to develop and validate these advanced motor components, indicating a TRL of 3 to 4. It is focused on engineering and characterizing materials and optimizing designs through simulation and AI, rather than being a commercially available product.
About Brunel University London
Brunel University London is a comprehensive public research university in West London with a campus-based community and an applied, industry-engaged ethos. Co-located labs and a science park adjacent to campus provide space for collaborative R&D, while proximity to Heathrow and major transport links makes partnering and pilot deployment straightforward. A strong placement tradition and professional practice pathways connect companies with student and alumni talent for internships and recruitment. Research is backed by competitive funding from UK Research and Innovation councils and Innovate UK, with additional support from national health research bodies. A dedicated technology transfer office manages IP, licensing, and spinouts, and enterprise programs support SMEs and corporate innovation.
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