The Crucial Role of Thermal Management in Electric Vehicles: Optimizing Electric Motor Housing Cooling Systems through Additive Manufacturing

In recent years, additive manufacturing has assumed a pivotal role as an innovative and disruptive technology across various industries, particularly in automotive. This cutting-edge technology has enabled the realization of solutions previously deemed unimaginable, reshaping the landscape of design and production. This study delves into the indispensable role of additive manufacturing within the realm of electric mobility, shedding light on its implications for future advancements through a comprehensive analysis of the current state of the art. Special emphasis has been placed on thermal management, a cornerstone in electric vehicle design that demands meticulous consideration and precision engineering. In this case study, the focus of optimization lies on the housing of an electric motor. Originally designed for air cooling, it underwent a transformative evolution, custom-tailored into a liquid cooling system through an additive design approach. This innovative design integrates internal cooling channels crafted using generative design principles, significantly enhancing overall heat dissipation and extending the operational lifespan of the electric motor. The original component was subjected to a careful reverse engineering process, followed by precise validation through measurements previously conducted in the laboratory. Subsequently, the thermal values of the original component were compared with those derived from the simulations of the new component, engineered ad hoc through additive manufacturing. This thesis highlights the transformative ability of additive manufacturing in reshaping electric vehicle design paradigms, particularly through the facilitation of refined and advanced thermal management strategies.