PRODUCTS MATERIALS IN DESIGN & PROTOTYPING


HIGH-VOLTAGE E-MOTOR BENEFITS FROM THE USE OF ADVANCED MATERIALS


Syensqo’s Ajedium PEEK (polyetheretherketone) slot liners and slot wedges, and KetaSpire PEEK magnet wire insulation, have been selected by Mavel Powertrain for their latest high-voltage electric motor for a renowned premium sports car manufacturer. According to the company, the combination of Ajedium PEEK slot liners and monolayer KetaSpire PEEK magnet wire enhances electric motor efficiency, supporting operations at over 800 volts. These materials’ reduced thickness allows for more copper in the motor design, improving electrical output and thermal management. “We are excited to collaborate


with Syensqo and integrate their advanced Ajedium and KetaSpire PEEK solutions into our latest high- voltage electric motor,” said Luca Favre, head of Motor Development at Mavel Powertrain. “Material excellence is at the core of our commitment to delivering cutting- edge electric powertrains to our automotive customers.”


Syensqo syensqo.com


ADDITIVE MANUFACTURING FOR SPACE THERMAL MANAGEMENT SOLUTIONS


ADVANCED MATERIALS PROVIDE A SUSTAINABLE FUTURE FOR AEROSPACE WIRING


Reducing environmental impact while maintaining high safety and performance standards is essential in aerospace applications. Lower weight is critical to improving fuel efficiency and reducing emissions – for one kilogram of weight saved, an aircraft saves approximately 0.03kg of fuel per 1,000km, which translated to a saving of around 0.0945kg of


carbon dioxide (CO2) emissions per 1,000km. Considering this, even the smallest weight change in wiring systems can make a difference. This is why manufacturers have started to implement innovative weight saving materials – like aluminium alloy conductors, carbon fibre composites or polytetrafluoroethylene (PTFE) jacketing – into airborne cable systems. While aerospace cabling has traditionally relied on copper


Severe temperature fluctuations in space can damage sensitive spacecraft components, resulting in mission failure. To help overcome this, 3D Systems is collaborating with researchers from Penn State University and Arizona State University on two projects – sponsored by the National Aeronautics & Space Administration (NASA) – intended to enable ground-breaking alternatives to current thermal management systems. Combining applications expertise with 3D Systems’ Direct Metal Printing (DMP)


technology and tailored materials, and Oqton’s 3DXpert software, the teams are engineering sophisticated thermal management solutions for the demands of next-generation satellites and space exploration. The project has resulted in processes to build embedded high-temperature


passive heat pipes in heat rejection radiators that are additively manufactured in titanium. These heat pipe radiators are 50% lighter per area with increased operating temperatures compared with current state-of-the-art radiators, allowing them to radiate heat more efficiently for high power systems. In addition, a project led by researchers at Penn State University and NASA Glenn


Research Center with 3D Systems’ AIG yielded a process to additively manufacture one of the first functional parts using nickel titanium (nitinol) shape memory alloys that can be passively actuated and deployed when heated. This passive shape memory alloy (SMA) radiator is projected to yield a deployed-to-


stowed area ratio that is six times larger than currently available solutions, enabling future high-power communications and science missions in restricted CubeSat volume. When deployed on spacecraft, such as satellites, these radiators can raise


operating power levels and reduce thermal stress on sensitive components, preventing failures and prolonging satellite lifespan. The team again used 3DXpert to design the deployable spoke structure of the


radiator. This was then 3D printed in nitinol (NiTi), a nickel-titanium shape memory alloy, using 3D Systems’ DMP technology. When affixed to a spacecraft such as a satellite, this device can be passively actuated and deployed when heated by fluid inside, thus removing the need for motors or other conventional actuation in space.


3D Systems 38 DESIGN SOLUTIONS JULY/AUGUST 2025 www.3dsystems.com


thanks to its excellent conductivity, its density contributes heavily to an aircraft’s weight. So, aluminium (AI) alloy conductors have infiltrated the market as a popular alternative to copper. Usually comprised of aluminium, copper, iron and magnesium, each metal’s individual properties contribute to the conductor’s resistance, creep resistance and strength. While AI alloys don’t quite match up to copper’s


conductivity amounting to 60% of copper’s conductivity level, they offer up to 50% weight reduction in wiring applications with the equivalent electrical resistance. This makes it suitable for avionic systems. In addition, composite polytetrafluoroethylene (PTFE)


jackets in aerospace wiring enable increased durability and resistance, crucial to longer operational lifespans while reducing footprint and weight. PTFE jackets offer superior abrasion resistance, chemical resistance and operational performance in temperatures up to 260˚C. This increased durability leaves cables with a service lifespan up to 30 years, minimising regular replacement and waste. Fibre optic cables are another advancement focusing on both performance and quality. Constructed from glass fibres, they are lighter than metal core cables typically weighing approximately just four pounds per 1,000 feet, while copper cable weighs around 39 pounds per 1,000 feet. It also offers higher bandwidth supporting transfer speeds up to 10 Gigabit per second (GBPS) and immunity to electromagnetic interference (EMI). In aerospace applications, fibre’s improved signal integrity


reduces the need for excess heavy shielding and simplifies cable design, substantially reducing in an aircraft’s weight. Adopting sustainable, high-performance cabling that also meets industry standards, is a process accelerated by supply chain partners like WireMasters.


WireMasters www.wiremasters.com/services


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