3D-Printable Metallic Glass Alloys Could Cut Electric Motor Energy Losses

Key Takeaways

• Three iron‑based metallic glasses printable via laser powder bed fusion
• Amorphous structure cuts hysteresis losses, boosting motor efficiency
• Alloys avoid cobalt, improving sustainability and supply security
• Potential range extension for e‑bikes, drones, and appliances
• Scaling 3D‑printing process is next industrial challenge

Summary

Researchers at Saarland University have identified three iron‑based metallic‑glass alloys that can be fabricated with laser powder‑bed fusion 3D printing. The amorphous composition eliminates crystal‑lattice friction, dramatically reducing hysteresis (iron) losses in electric‑motor stators and rotors. These alloys contain 70‑80% iron and avoid critical elements such as cobalt, offering both performance gains and sustainability benefits. The EU‑funded AM2SoftMag consortium is now focused on scaling the process for industrial motor production.

Pulse Analysis

The emergence of printable metallic‑glass alloys marks a turning point for magnetic material engineering. Unlike conventional crystalline steels, these iron‑based glasses freeze into a disordered atomic arrangement, allowing magnetic domains to reorient with minimal resistance. Laser powder‑bed fusion provides layer‑by‑layer control, preserving the amorphous state and enabling complex geometries that were previously impossible with bulk metallic glasses. This combination of material science and additive manufacturing opens a new design space for high‑performance motor components.

From an efficiency standpoint, the elimination of crystal‑lattice friction cuts hysteresis losses, the dominant source of heat in small, high‑speed motors. Early prototypes show measurable reductions in iron loss, which directly improves the energy‑to‑motion conversion ratio. By removing cobalt—a critical, price‑volatile element—from the alloy composition, manufacturers gain a more resilient supply chain and lower environmental impact. These gains are especially relevant for e‑bikes, drones, and household appliances where every watt saved extends range or reduces operating costs.

The next hurdle is scaling the laser‑based 3D printing process from laboratory to mass production. The AM2SoftMag consortium, comprising universities and industrial partners such as Heraeus AMLOY Technologies, is refining process parameters to ensure repeatable glass formation across large batches. Successful industrialization could reshape the electric‑motor market, prompting OEMs to adopt amorphous components for next‑generation devices. As efficiency standards tighten and sustainability mandates grow, printable metallic glasses are poised to become a strategic material for the future of electrified mobility and smart appliances.