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.
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The Origin
I'm Jørgen Selnes, CEO & 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
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Custom Shape & Size
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Non-skewed Windings
Moulding
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.
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Custom Shape & Size
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.
High Copper Fill Factor
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.
Non-Skewed Windings
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.