NovaCentrix HPS-FG77 Conductive Ink Helps Enable Fully Additive Electromechanical Systems
Earlier this year, we highlighted research from the Sensing Technologies Laboratory at Georgia Tech, led by Prof. Ellen Yi Chen Mazumdar, demonstrating a fully additively manufactured multilayer motor stator enabled by NovaCentrix HPS-FG77 silver nanoparticle ink. That work showed how conductive inks could move beyond simple printed traces and function as high-current electromagnetic components within electric machines. A newly published paper from the same research group now takes that vision significantly further. Published in Advanced Materials Technologies, Fully 3D-Printed Wave-Wound Electromagnetic Motors demonstrates fully 3D-printed electromagnetic motors and actuators manufactured using a novel multimaterial additive manufacturing process. Excluding permanent magnets, the work demonstrates the use of 3D printing to manufacture nearly all motor elements—including stators, housings, bearings, sensing circuits, and structural components—within a single integrated manufacturing approach.
Why This Matters
Additive manufacturing has long promised the ability to fabricate complete electromechanical systems directly from digital designs. While significant progress has been made in structural components and low-power electronics, high-current electromagnetic devices have remained difficult to manufacture due to limitations in materials, thermal management, and conductor architectures. This research addresses those challenges through a new multilayer wave-winding topology specifically designed for additive manufacturing. By combining conductive silver nanoparticle inks, thermally conductive but electrically insulating polymers, and embedded surface-mount electronics, the team created fully functional electromagnetic devices that significantly outperform previous printed motor demonstrations. Importantly, this paper represents a clear continuation of the Sensing Technologies Laboratory’s broader effort to develop fully additively manufactured electromechanical systems. While the group’s earlier work focused on proving that multilayer electromagnetic stators could be fabricated using conductive inks and additive manufacturing techniques, this latest publication expands the concept to complete motor architectures and functional robotic systems. The result is not simply a printed motor component—it is a step toward fully printed machines.
The Role of NovaCentrix HPS-FG77
At the heart of the manufacturing process is NovaCentrix HPS-FG77 silver nanoparticle ink, which serves as the conductive material for the multilayer electromagnetic windings. As demonstrated in the group’s previous motor stator research, HPS-FG77 provides a combination of properties required for demanding additive manufacturing environments, including:
- High viscosity for stable deposition of complex 3D geometries
- Compatibility with multimaterial printing processes
- Low-temperature sintering suitable for integration with polymer structures
- Reliable formation of multilayer conductive pathways capable of carrying substantial current
These characteristics enabled the fabrication of densely integrated wave-wound electromagnetic structures that would be difficult—or impossible—to manufacture using conventional additive techniques. More importantly, the conductive traces function as true electromagnetic windings rather than simple interconnects, highlighting the growing role of conductive inks as active functional materials within electromechanical systems.
Record Performance for Printed Motors
The researchers demonstrated multiple motor architectures, including:
- Axial flux motors
- Cylindrical radial flux motors
- Linear motors
Among the reported results, the axial flux motor achieved a peak torque constant of 7.62 N·mm/A and a maximum efficiency of 28.2%. According to the paper, this represents approximately 5× higher torque generation capability and 3.7× higher efficiency than prior printed motor demonstrations. These results represent a substantial advancement for fully additively manufactured electromagnetic devices and demonstrate that printed motors can achieve meaningful electromechanical performance rather than serving solely as proof-of-concept demonstrations.
From Components to Complete Systems
Perhaps the most compelling aspect of the work is the breadth of functional demonstrations enabled by the printed actuators. The researchers used the motors to power:
- A fan
- A water pump
- A paddle-wheel boat
- A multi-legged walking robot
- A robotic waving arm
These examples illustrate an important shift in additive manufacturing research. Rather than focusing on individual printed components, researchers are increasingly building complete systems that integrate structures, electronics, sensing, and actuation within a unified manufacturing workflow.
Looking Ahead
The progression from fully additively manufactured stators to fully 3D-printed motors and robotic systems highlights the rapid advancement of the research being conducted by Prof. Ellen Yi Chen Mazumdar’s Sensing Technologies Laboratory at Georgia Tech. The group’s work shows a clear path from printed electromagnetic components toward integrated electromechanical systems capable of powering real-world applications. As additive manufacturing platforms, materials, and design methodologies continue to evolve, the ability to fabricate complete electromechanical devices directly from digital models becomes increasingly realistic. Conductive materials capable of functioning reliably within these demanding environments will play a critical role in enabling that future. At NovaCentrix, we are excited to see HPS-FG77 helping researchers push the boundaries of what can be manufactured through additive processes. This work represents another important milestone toward fully integrated printed machines, robots, and next-generation electromechanical systems.
➡️ Read the full paper:
Fully 3D-Printed Wave-Wound Electromagnetic Motors, Advanced Materials Technologies, DOI: 10.1002/admt.70994
➡️ Read our earlier related post:
Enabling Fully Additive Electric Motors: The Role of Conductive Inks in Next-Generation Manufacturing