Reimagining Hairpin Windings: 3D Transposition through Additive Manufacturing

Abstract

This research investigates the adaptation of Roebel transposition principles to hairpin windings for low-voltage, highcurrent operation. A series of conductor configurations, includingsubdivision into subconductors and 3D in-slot transposition, were analyzed to mitigate circulating currents and optimize AC loss distribution. Additive manufacturing was explored as an enabling technology to realize complex conductor geometries while maintaining insulation integrity. The results demonstrate that optimized conductor segmentation and height variation can reduce AC losses by over 50% compared to the reference design, providing a viable pathway for compact, highperformance electric machines suitable for modern electrified mobility applications.