Abstract
This paper investigates the engineering and technological potential of additive manufacturing technologies in electric machine structures. The relevance of the study is determined by the need to reduce material consumption, manufacture complex geometries with internal cooling channels, and improve production flexibility in the design and manufacturing of electric machines.The aim of the study is to perform a comparative engineering analysis of additive manufacturing technologies used in electric machine structures and to evaluate their mechanical reliability through CAD/CAE-based numerical simulation.The study compares LPBF, microextrusion, and cold spray technologies in terms of manufacturing accuracy, surface quality, material limitations, and technological efficiency. A parametric three-dimensional rotor model was developed in the SolidWorks CAD environment, and its stress–strain state under centrifugal loading was analyzed using SolidWorks Simulation.The scientific novelty of the research lies in the original CAD/CAE-based engineering assessment of the mechanical reliability of an electric machine rotor designed for additive manufacturing. The simulation results showed that the maximum von Mises stresswas 1.189×10⁷ Pa, the maximum displacement was 9.748×10⁻⁴ mm, and the calculated safety factor reached 52.2, indicating a high level of structural reliability.The obtained results demonstrate that additive manufacturing technologies provide opportunities to reduce rotor mass, create complex geometries, and improve the energy efficiency of electric machines.