MIT Develops Multi-Material 3D Printer That Produces Complete Electric Motors in 3 Hours

One-Step Electric Motor Manufacturing

Researchers at MIT have created a 3D printing platform capable of producing electric motors using multiple functional materials in a single process. The system uses four specialized extruders that can handle different forms of printable materials, including electrically conductive and magnetic materials.

Five Materials, One Process

The research team used their platform to produce a fully functional electric linear motor in approximately three hours using five different materials. The motor required only one post-processing step—magnetizing the hard magnetic materials—to become fully operational.

Material costs for each device are estimated at around 50 cents.

Significant Engineering Challenges

The custom-built system required significant engineering work to integrate different extrusion methods into one platform.

"There were significant engineering challenges. We had to figure out how to marry together many different expressions of the same printing method—extrusion—seamlessly into one platform," says Luis Fernando Velásquez-García, senior author of the study published in Virtual and Physical Prototyping.

Performance Matched or Exceeded

The 3D-printed linear motor demonstrated performance equal to or better than similar motors made through more complex manufacturing processes. Linear motors generate straight-line motion and are commonly used in robotics, optical systems, and conveyor applications.

On-Site Manufacturing Potential

The technology could potentially enable on-site manufacturing of electronic components for various industries, reducing reliance on distant suppliers and lengthy production delays. Imagine a world where you can print a replacement motor on demand rather than waiting for shipping from a distant factory.

What's Next

The researchers plan to integrate the magnetization process directly into the printing workflow and work toward fabricating rotary motors. They also aim to add more tools to enable production of more complex electronic devices through this single-step manufacturing approach.

The Bigger Picture

This breakthrough represents a significant step toward fully additive electronics manufacturing. Rather than assembling electric motors from separately manufactured components, this approach prints the entire device in one go.

As the technology matures, it could democratize access to custom electric motors and other electromagnetic devices, enabling small manufacturers and even hobbyists to create specialized motors for their specific needs.