BUP64 - BiFra-EM

Bionic-Inspired Fractal Structures for the Electric Motors of the Future (BiFra-EM)

Electrical machines are key components of the energy transition and provide the foundation for technological progress in applications such as electromobility and sustainable aviation. A critical factor for their efficiency and power density is the air gap between rotor and stator. This project investigates how bionically inspired fractal surface structures can enlarge the interaction surfaces and thus optimize the air gap. The aim is to analyze the fundamental potential of such structures and to demonstrate their contribution to the optimization of electrical machines.

Aim

The aim of this project is to investigate and demonstrate the potential of fractal surface structures for optimizing the air gap in electrical machines. It is to be shown that these structures can significantly increase the effective air-gap area and thereby enhance the magnetic flux at the same current loading. As a result, the efficiency and power density of the electrical machine can be enhanced.

 

Approach

  • Development, simulation, and selection of suitable fractal microstructures
  • Selection of an appropriate manufacturing method
  • Fabrication of test specimens with different air-gap structures and setup of a test bench
  • Experimental validation
  • Transfer of measurement results to a machine model to predict potential performance improvements


Benefits

The use of fractally structured air gaps is fundamentally suitable for all types of electrical machines. It enables improvements in efficiency and power density across a wide range of applications. For end users, this results in more powerful, more efficient, and more environmentally friendly electrical drives.

Key data

Research Field

Mobility Technologies

Period

19.01.2026 until 19.10.2026

Project participants

University of Stuttgart: Institute of Electrical Energy Conversion (iew, Yuancong Gong, Benedikt Kaiser)