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Induction machines (IM) are considered work horse for industrial applications due to their rugged, reliable and inexpensive nature; however, their low power density restricts their use in volume and weight limited environments such as an aerospace, traction and propulsion applications. Given recent advancements in additive manufacturing technologies, this paper presents opportunity to improve power density of induction machines by taking advantage of higher slot fill factor (SFF) (defined as ratio of bare copper area to slot area) is explored. Increase in SFF is achieved by deposition of copper in much more compact way than conventional manufacturing methods of winding in electrical machines. Thus a design tradeoff study for an induction motor with improved SFF is essential to identify and highlight the potentials of IM for high power density applications and is elaborated in this paper.

Energy storage options for a hybrid electric commercial single aisle aircraft were investigated. The propulsion system features twin Geared Turbofan™ engines in which each low speed spool is assisted by a 2,500 HP electric motor during takeoff and climb. During cruise, the aircraft is powered solely by the turbine engines which are sized for efficient operation during this mission phase. A survey of state of the art energy storage options was conducted. Battery, super-capacitor, and flywheel metrics were collected from the literature including Specific Energy (Wh/kg), Volumetric Energy Density (Wh/L), Specific Power (W/kg), Cost ($/kWh), and Number of Cycles. Energy storage in fuels was also considered along with various converters sized to produce a targeted quantity of electric power. The fuel and converters include fuel cells (both proton exchange membrane and solid oxide operating on hydrogen or on jet fuel) and a turbogenerator (jet fuel or LNG).

Induction machines (IM) are considered work horse for industrial applications due to their rugged, reliable and inexpensive nature; however, their low power density restricts their use in volume and weight limited environments such as an aerospace, traction and propulsion applications. Given recent advancements in additive manufacturing technologies, this paper presents opportunity to improve power density of induction machines by taking advantage of higher slot fill factor (SFF) (defined as ratio of bare copper area to slot area) is explored. Increase in SFF is achieved by deposition of copper in much more compact way than conventional manufacturing methods of winding in electrical machines. Thus a design tradeoff study for an induction motor with improved SFF is essential to identify and highlight the potentials of IM for high power density applications and is elaborated in this paper.