Additive manufacturing enables the production of complex geometries extremely difficult to create with conventional subtractive methods. While good at producing complex parts, its limitations can be seen through its penetration into everyday manufacturing markets. Throughput limitations, poor surface roughness, limited material selection, and repeatability concerns hinder additive manufacturing from revolutionizing all but the low-volume, high-value markets. This work characterizes combining powder-binder jetting with traditional casting techniques to create large, complex metal parts. Specifically, we extend this technology to wind turbine generators and provide initial feasibility of producing complex direct-drive generator rotor and stator designs. In this process, thermal inkjet printer heads selectively deposit binder on hydroperm casting powder. This powder is selectively solidified and baked to remove moisture before being cast through traditional methods. This work identifies a scalable manufacturing process to print large-scale wind turbine direct drive generators. As direct-drive generators are substantially larger than their synchronous counterparts, a printing process must be able to be scaled for a 2–5 MW 2–6m machine. For this study, research on the powder, binder, and printing parameters is conducted and evaluated for scalability.

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