Use Case: Use of 3D printing at DeepDrive

How 3D printing supports the development of innovative drive units: Use case for copper components

The drive unit is the centrepiece of every electric vehicle. It determines how far, how fast and how efficiently the vehicle can travel. New innovations are therefore constantly in demand to improve the performance and economy of electric vehicles. One of these is the dual-rotor motor technology developed by the high-tech company DeepDrive. This technology makes it possible to increase the range of electric vehicles by up to 20% and significantly reduce costs compared to conventional combustion engines.

To realise this innovative technology, DeepDrive needed a special component made of pure copper that serves as a connecting piece between wires in their stator. "At first, we weren't sure whether it was even possible to additively manufacture these small, complex particles from pure copper. PROTIQ succeeded and we are very happy with the result," explains Xenia Presser-Velder from DeepDrive.

The small components (7mm x 3mm x 8mm) have an angled geometry that makes it difficult to produce using other manufacturing techniques. In addition, the components had to be made of very conductive material in order to connect the wires together effectively. 

To fulfil these requirements, 3D printing using the SLM process (selective laser melting) was chosen. This involves using a laser beam to melt a fine metal powder layer by layer to create the desired component. With this process, the copper components could be printed with high precision and quality without any deformation or cracks. The small size and quantity also meant that production was possible in the shortest possible time.

The result was perfectly fitting, functional and highly conductive copper components that were installed in DeepDrive's drive unit and were thus able to contribute to the development and production of innovative drive units.

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About DeepDrive

DeepDrive, a pioneering high-tech company based in Munich, develops drive units for electric vehicles. With its patented dual-rotor motor technology, DeepDrive addresses two of the biggest challenges facing electric vehicles: limited range and higher costs compared to conventional combustion engines. With DeepDrive's advanced motor solutions, electric vehicles can now achieve up to 20% greater range at significantly reduced costs, making sustainable transport solutions more accessible.

The company has received significant recognition in the industry and is currently working with eight of the ten leading car manufacturers on various development projects. In addition, DeepDrive is supported by renowned investors such as BMW i Ventures, the Corporate Venture Capital Unit of Continental, UVC Partners and Bayern Kapital. Dr Peter Mertens, former CTO of Audi and Volvo, and Jonas Rieke, COO of Personio, continue to contribute to DeepDrive's momentum.

Images: DeepDrive