Abstract: A method for manufacturing an electro-mechanical device includes creating a plurality of substrates using a first additive manufacturing process. Each of the substrates includes a polymeric material. The substrates include a first substrate and a second substrate. The first substrate includes a first main body and defines a protrusion extending from the first main body. The second substrate includes a second main body and a recess defined in the second main body. The method includes coupling the first substrate to the second substrate by inserting the protrusion into the recess such that the protrusion elastically deforms to an elastically averaged configuration. The protrusion and the recess together form an elastic averaging coupling. The method includes creating a plurality of electrically conductive components using a second additive manufacturing process and then coupling the electrically conductive components to at least one of the substrates.

Abstract: A method for manufacturing an electro-mechanical device includes creating a plurality of substrates using a first additive manufacturing process. Each of the substrates includes a polymeric material. The substrates include a first substrate and a second substrate. The first substrate includes a first main body and defines a protrusion extending from the first main body. The second substrate includes a second main body and a recess defined in the second main body. The method includes coupling the first substrate to the second substrate by inserting the protrusion into the recess such that the protrusion elastically deforms to an elastically averaged configuration. The protrusion and the recess together form an elastic averaging coupling. The method includes creating a plurality of electrically conductive components using a second additive manufacturing process and then coupling the electrically conductive components to at least one of the substrates.

Abstract: An electric machine includes a stator and a rotor lamination assembly. The rotor lamination assembly may be configured and disposed relative to the stator. The rotor lamination assembly includes at least one lamination member wherein the lamination member defines at least magnet receiving aperture and a fastening region. The lamination member further includes a body disposed between an inner diametric edge and an outer diametric edge. The magnet receiving aperture includes a first end which extends to a second end such that the second end is spaced from the outer diametric edge to define a bridge region. The fastening region engages with a receiving region in a rotor shaft via an interference fit to generate a tensile load (or pre-load) in the body.