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FiberPrinting™
Alva’s next-gen electric motors & propulsion systems are manufactured by our patented FiberPrinting™ technology. This groundbreaking & 6 time patented process enables us to rapidly design & manufacture ironless & slotless windings with high copper fill factor for any electric motor or generator, setting a new standard in precision, torque-density & adaptability.
The origin
I'm Jørgen Selnes, CSO & co-founder of Alva. Let's rewind to where it all started, in my parents' garage in Oslo, Norway, while I was still studying at NTNU. What began as a passion project grew into a journey of innovation in electric motor technology. With inspiration & support from great team members, we transformed our startup dreams into the Alva powerhouse.
Innovative manufacturing of stators
FiberPrinting™ is an industrial winding method that allows for continuous winding of stator mats for ironless & slotless rotary & linear motors. This method maximizes copper fill factor & enable precise customization of size & stator configuration, resulting in the optimal combination of torque-density & precision in any size & form-factor.
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60% Copper Fill Factor
Minimal electric resistance.
Custom Shape & Size
Rotary, Linear & arc stators in any size.
Non-skewed Windings
Maximised torque output.
Our automised moulding process transforms the FiberPrinted™ stator mat into a structural component with tight tolerances. Automation is integral, reducing costs & improving quality by minimizing part-to-part deviation. Additionally, we offer flexibility in resin types, tailoring them to specific applications, such as using fill resin for thermal performance or water-compatible resin for marine applications.
The versatility & flexibility of the FiberPrinting™ process allow for the manufacturing of stator mats in a variety of shapes & sizes. These stator mats can be produced in any length, width, thickness, & pole size. Additionally, FiberPrinted™ stator mats can be further processed into both rotary or linear precision motors.
The primary limitation of traditional ironless & slotless motors lies in their poor performance in terms of power & torque density. This is mainly attributed to the low copper fill factor, which compromises phase resistance & voltage constant.
FiberPrinting™ addresses this limitation by enabling a high copper fill factor, up to 60%, & short end-windings. These advancements significantly boost the performance of slotless motors, allowing them to even challenge slotted motors in terms of performance.
The low copper fill factor is not the sole limitation of traditional ironless & slotless motors. Traditional ironless & slotless winding methods can only produce skewed windings. These skewed windings generate a magnetic field that is misaligned with the rotor's magnetic field, resulting in a lower motor constant (Km).
FiberPrinting™ allows for the production of non-skewed stator windings with a magnetic field that is perfectly aligned with the rotor's magnetic field, massively improving performance in terms of power & torque density.
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