Abstract: A 3D printed metal coil for an electrical machine. The 3D printed coil has a plurality of turns and is configured to fit within a slot in an electrical machine. A cross-sectional shape of successive turns of the plurality of turns varies such that a portion of each turn forms a part of an external surface of the metal coil, the external surface forming an interface with a side of the slot.

Abstract: A 3D printed metal coil for an electrical machine. The 3D printed coil has a plurality of turns and is configured to fit within a slot in an electrical machine. A portion of each turn forming an end winding of the coil has a flat plate-like shape for dissipating heat from the end winding.

Abstract: A method is provided for fabricating an insulated metal coil for an electrical machine. The method includes 3D printing a metal coil having a plurality of turns. The method further includes subsequently infiltrating insulating material between the turns of the metal coil to electrically insulate the turns from each other.

Abstract: A method of manufacturing a magnetically graded material, including depositing a steel filler material to a substrate, and applying a directed energy source to first and second regions of the filler material to thereby join the filler material to form a joined material. The energy source is directed to the first region while the first region is provided with an inert shield gas such that the material of the first regions includes a magnetic phase, and the energy source is directed to the second region while the second region is provided with a nitrogen containing shield gas to thereby impart an non-magnetic phase to the joined material.

Abstract: A method is provided for fabricating an insulated metal coil for an electrical machine. The method includes 3D printing a metal coil having a plurality of turns. The method further includes subsequently infiltrating insulating material between the turns of the metal coil to electrically insulate the turns from each other.

Abstract: A method of manufacturing a magnetically graded material, including depositing a steel filler material to a substrate, and applying a directed energy source to first and second regions of the filler material to thereby join the filler material to form a joined material. The energy source is directed to the first region while the first region is provided with an inert shield gas such that the material of the first regions includes a magnetic phase, and the energy source is directed to the second region while the second region is provided with a nitrogen containing shield gas to thereby impart an non-magnetic phase to the joined material.

Abstract: A method of sintering a metal injection-moulded, green aerofoil component. The method includes providing a setter having a stationary support arranged to support an aerofoil part of the component and a moveable platform arranged to support an end part of the component, the moveable platform being independently moveable relative to the stationary support. The method further includes locating the green component on the setter such that the aerofoil part and the end part are supported by respectively the stationary support and the moveable platform. The supported green component is then sintered, the moveable platform moving during the sintering relative to the stationary support to accommodate sintering-induced shrinkage of the component.

Abstract: An additive layer manufacturing method includes the steps of: a) laying down powder layer on powder bed, and b) focussing energy on an area of powder layer to fuse area of powder layer and thereby form a cross-section of the product; wherein steps a) and b) are repeated to form successive cross-sections of product, and wherein at least one of said steps b) involves focussing energy on an area of respective powder layer which is unsupported by a previously formed cross-section of product to thereby form a downwardly facing surface of product. Method is at least some of said successive steps b) involve focussing energy on a support area of respective powder layer, to fuse support area and thereby form successive cross-sections of a support pin within powder bed, support pin extending outwardly from downwardly facing surface of product when it is formed, so as to support downwardly facing surface.