Metal Additive Manufacturing Conference - MAMC 2022

In Additive Manufacturing (AM), the method of Parametric Modeling (PM) is often used for the design development and creation of products. However, this approach is not yet widely used for the development of tools for production machines and processes. In the production of hairpin stators (an innovative technology for the copper winding of the static component of an electric motor for electric vehicles) in the field of e-mobility, the demands for variant-flexible production lines are increasing more and more in order to react to the short development cycles of electric motors in a more cost-efficient way.
Therefore, the goal is to achieve this variant flexibility in the production of hairpin stators through Parametric Modeling and Additive Tooling of production tools depending on product characteristics.
For this purpose, parametric models of developed tools are generated by implementing design algorithms in parametric design software. By varying the input parameters, which are the properties of the product to be produced (stator of an e-motor), the required variant flexibility is validated. The work is exemplified for one production step of hairpin stator production on a clamping tool for welding hairpins (copper conductors).
The results are discussed and the potential of achieving variant flexible production lines by Parametric Modeling and Additive Tooling is evaluated.