Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAMOver two million euros in funding for innovative research infrastructure – the SIREN project aims to reduce dependence on critical raw materials and enable new engine designs
Fraunhofer IFAM Dresden is developing new manufacturing technologies for resource-independent electric motors
High-performance electric motors are key components of modern mobility and numerous industrial applications. However, their manufacture often relies on critical raw materials such as rare earths and copper. The Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM in Dresden aims to significantly reduce these dependencies in future. As part of the new SIREN project, an innovative research infrastructure is being established to enable the development and manufacture of next-generation, resource-efficient electric motors. The Free State of Saxony and the European Union are supporting the project with funding of more than two million euros.
New materials and manufacturing processes for powertrain technology
The SIREN project – “Sovereign and versatile infrastructure for next-generation, resource-independent electric drives” – focuses on establishing an end-to-end, sinter-based additive manufacturing process chain that opens up new possibilities for the production of electric drives.
Unlike conventional manufacturing processes, this enables different metallic materials to be combined in a targeted manner and complex component geometries to be produced which, until now, have been difficult or impossible to manufacture. This lays the foundation for innovative, high-performance and, at the same time, resource-efficient engine designs.
Particular emphasis is placed on the development of so-called multi-material laminated stacks, in which soft magnetic and non-magnetic materials are specifically combined. These enable innovative motor architectures, for example for high-speed reluctance motors and ferrite-excited permanent magnet drives that can operate without rare earths.
Another research approach involves replacing copper with aluminum in electrical windings. By incorporating special cooling channels, the aim is to specifically improve the properties of the aluminum windings and open up new possibilities for high-performance electric drives.
Less dependence on raw materials, greater technological autonomy
The availability of critical raw materials is a key challenge for European industry. In the case of rare earths in particular, there is a high degree of dependence on a small number of supplier countries. Copper, too, is a strategically important raw material in view of rising demand, driven in part by the electrification of transport and industry.
By developing alternative materials and innovative manufacturing processes, Fraunhofer IFAM Dresden is helping to strengthen Europe’s sovereignty in raw materials and technology. At the same time, these new technologies open up potential for more efficient use of materials and the development of high-performance electric drive systems.
The research focuses in particular on demanding mobility applications where compact designs, high power densities and reliable drive systems are required. These include, amongst others, air, land and underwater vehicles. Furthermore, the technologies developed offer prospects for further industrial applications.
Unique research infrastructure for technology transfer
With the SIREN project, Fraunhofer IFAM Dresden is expanding its expertise in powder metallurgy and additive manufacturing to include a novel combination of processes for the production of electric drives. This planned integration of technologies is unique in Europe in this form.
The aim is to map the entire process chain, from materials development through the manufacture of complex components to fully functional demonstrators. The infrastructure is also intended to serve as a basis for transferring the developed technologies into industrial applications.
Particular emphasis is placed on collaboration with companies in the fields of drive technology, the supply industry and sintering technology. By providing the research infrastructure and facilitating targeted knowledge and technology transfer, the aim is, in particular, to give small and medium-sized enterprises in Saxony access to innovative manufacturing processes and enable them to strengthen their position within European value chains.
Funding strengthens Saxony’s position as a centre for research and industry
Fraunhofer IFAM Dresden is to receive funding of more than two million euros until the end of 2028 to establish the new research infrastructure. The funds are being provided from the European Regional Development Fund (ERDF) under the “InfraProNet Research 2021–2027” funding scheme of the Saxon State Ministry for Science, Culture and Tourism. The funding is being granted by the Sächsische Aufbaubank – Förderbank – (SAB).
The project also supports the objectives of the European Platform for Strategic Technologies (STEP), which aims, amongst other things, to strengthen the development and manufacture of resource-efficient and strategically important technologies in Europe.
With SIREN, Fraunhofer IFAM Dresden is creating new conditions for developing innovative electric drive technologies in collaboration with industry partners, thereby contributing to a resource-efficient, competitive and independent European industry.
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