MIT Builds 3D Printer That Creates Working Electric Motors in One Step

MIT researchers have created a groundbreaking 3D printing platform capable of producing fully functional electric motors using multiple functional materials in a single process. The system could revolutionize how we manufacture electric machines.

One Printer, Five Materials

The custom-built platform uses four specialized extruders that can handle different forms of printable materials, including electrically conductive and magnetic materials. The printer seamlessly switches between extruders as it builds devices layer by layer.

Using this platform, the team produced 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.

50 Cents Per Motor

Material costs for each device are estimated at around 50 cents. The 3D-printed linear motor demonstrated performance equal to or better than similar motors made through more complex traditional manufacturing processes.

Linear motors generate straight-line motion and are commonly used in robotics, optical systems, and conveyor applications.

Significant Engineering Challenges

According to Luis Fernando Velásquez-García, senior author of the study published in Virtual and Physical Prototyping: 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.

Future Applications

The technology could enable on-site manufacturing of electronic components for various industries, reducing reliance on distant suppliers and lengthy production delays. The researchers plan to:

• Integrate the magnetization process directly into the printing workflow
• Work toward fabricating rotary motors (the kind found in most electric vehicles)
• Add more tools to enable production of more complex electronic devices

What This Means

This research represents a significant step toward single-step manufacturing of complex electromagnetic devices. While the current system produces linear motors, the implications for manufacturing electric vehicles, drones, and other electric machinery could be substantial.

The ability to print functional motors in hours rather than weeks, at a fraction of the cost, could democratize access to custom motor designs.