3D Printed Liquid Cooled Jacket
Problem statement
A major constraint with high-performance motors such as Formula E electric motors is that increasing the output torque also increases the heat generated within the motor winding’s. This extra heat causes increased temperatures that then lead to wire insulation to break down and magnets within the motor to demagnetize which causes overall motor failure. Extra heat generation can be dissipated by pumping a liquid into a cooling jacket wrapped around the motor and will be 3D printed to obtain unique geometries that improve its efficiency. The cooling jacket will maintain safe operating temperatures for the motor so that these higher torques can be obtained. This allows for more advancement in the Formula E field to design more efficient heat exchangers as each competitor strives for a faster vehicle. The possible materials for the jacket are copper and aluminum with thermal conductivities of 385 W/m-K [3] and 205 W/m*K [5] respectively. These materials allows for proper heat dissipation while not breaking down under high temperatures. The overall task is to balance geometric, thermal, and coolant constraints making a cooling jacket as small and light as possible while being capable of dissipating the required heat load.
Team members
Logan Kossel – leader 
Vince Zimmerman – communicator
Austin Carlson – accountant
Anthony Axberg – admin
Client
Brian Fehring, Arnold Magnetic