Methods for manufacturing a rotor assembly for an electrical machine

1. A method for manufacturing a rotor assembly for an electrical machine, the method comprising:

printing a first part of a rotor shaft;

printing a rotor core onto the first part of the rotor shaft;

printing a second part of the rotor shaft onto the rotor core;

printing a first part of a rotor winding;

coupling the first part of the rotor winding to the rotor core; and

after coupling the first part of the rotor winding to the rotor core, printing a second part of the rotor winding onto the first part of the rotor winding to form the rotor assembly.

2. The method of claim 1 , wherein printing the first part of the rotor shaft comprises printing the first part of the rotor shaft using a first material, and wherein printing the rotor core comprises printing the rotor core using a second material that is different than the first material.

3. The method of claim 1 , wherein printing the rotor core comprises:

printing a first lamination sheet;

printing at least one spacer after printing the first lamination sheet; and

printing a second lamination sheet after printing the at least one spacer,

wherein the at least one spacer is positioned between the first lamination sheet and the second lamination sheet.

4. The method of claim 3 , wherein the at least one spacer is formed from a first material having a high resistivity relative to a second material that is used to form the both the first lamination sheet and the second lamination sheet.

5. The method of claim 1 , wherein printing the rotor core comprises printing a first projection, wherein printing the first part of the rotor winding comprises printing a second projection, and wherein the first projection contacts the second projection when the first part of the rotor winding is coupled to the rotor core.

6. The method of claim 5 , further comprising:

applying a varnish or epoxy to the rotor assembly;

removing the first projection from the rotor core after applying the varnish or epoxy; and

removing the second projection from the first part of the rotor winding after applying the varnish or epoxy.

7. The method of claim 6 , wherein applying the varnish or epoxy to the rotor assembly comprises potting the epoxy to the rotor assembly.

8. The method of claim 6 , wherein applying the varnish or epoxy to the rotor assembly comprises electrophoretically depositing the varnish or epoxy onto the rotor assembly.

9. A method for manufacturing an electrical machine, the method comprising:

printing, by a three-dimensional (3D) printing process, a stator assembly;

printing, by the 3D printing process, a first part of a rotor shaft;

printing, by the 3D printing process, a rotor core onto the first part of the rotor shaft;

printing, by the 3D printing process, a second part of the rotor shaft onto the rotor core;

printing, by the 3D printing process, a first part of a rotor winding;

coupling the first part of the rotor winding to the rotor core; and

after coupling the first part of the rotor winding to the rotor core, printing, by the 3D printing process, a second part of the rotor winding onto the first part of the rotor winding to form a rotor assembly,

wherein the 3D printing process comprises fusing metal using laser energy or heat.

10. The method of claim 9 , further comprising printing, by the 3D printing process, a housing defining a cavity.

11. The method of claim 9 , wherein printing the first part of the rotor shaft comprises printing, by the 3D printing process, the first part using a first material, and wherein printing the rotor core comprises printing, by the 3D printing process, the rotor core using a second material that is different than the first material.

12. The method of claim 9 , wherein printing the rotor core comprises:

printing a first lamination sheet;

printing at least one spacer after printing the first lamination sheet; and

printing a second lamination sheet after printing the at least one spacer,

wherein the at least one spacer is positioned between the first lamination sheet and the second lamination sheet.

13. The method of claim 12 , wherein the at least one spacer is formed from a first material having a high resistivity relative to a second material that is used to form the first and second lamination sheets.

14. The method of claim 9 , wherein printing the rotor core comprises printing, by the 3D printing process, a first projection, wherein printing the first part of the rotor winding comprises printing, by the 3D printing process, a second projection, and wherein the first projection contacts the second projection contact when the first part of the rotor winding is coupled to the rotor core.

15. The method of claim 14 , further comprising:

applying a varnish or epoxy to the rotor assembly;

removing the first projection from the rotor core after applying the varnish or epoxy; and

removing the second projection from the first part of the rotor winding after applying the varnish or epoxy.

16. The method of claim 15 , wherein applying the varnish or epoxy to the rotor assembly comprises potting the epoxy to the rotor assembly.

17. The method of claim 15 , wherein applying the varnish or epoxy to the rotor assembly comprises electrophoretically depositing the varnish or epoxy onto the rotor assembly.

18. A method for manufacturing a rotor assembly for an electrical machine, the method comprising:

printing a rotor core;

printing a first part of a rotor shaft onto a first end of the rotor core;

printing a second part of the rotor shaft onto a second end of the rotor core;

printing a first part of a rotor winding;

coupling the first part of the rotor winding to the rotor core; and

after coupling the first part of the rotor winding to the rotor core, printing a second part of the rotor winding onto the first part of the rotor winding to form the rotor assembly.

19. The method of claim 18 , wherein printing the rotor core comprises:

printing at least one damp bar; and

printing a damp ring.

20. The method of claim 19 , further comprising:

inserting the at least one damp bar into a slot defined by the rotor core; and

coupling the damp ring to the rotor core after inserting the at least one damp bar into the slot.