3d Printed Brushless Motor

thingiverse

This is a 3D printed brushless motor I built for a school project, and it's still going strong. This motor is a three-phase brushless DC motor that can handle slow but high torque applications - just make sure to use the right ESC for this. Also, since it has a non-ferrite core (although you can boost efficiency by using ferrite-enforced PLA), it requires a spinning start to function properly (depending on how well you built it). My first version of this motor used 1/4-20 3 inch bolts, 1/4 ID x 5/8 OD bearings, 28 gauge magnet wire, and 1"x.5"x.125" nickel-plated rare earth magnets. To connect the motor, follow a standard three-phase V configuration - but a delta configuration might also work. To install the magnets, make sure to align them so that they alternate poles (there's an even number of slots, so this is possible), and glue them in place with cyanoacrylates. I've tested two iterations of this motor: the first one spun too fast and turned into a makeshift rotary IED, and we're still finding shrapnel all over the garage today. Then, I tested out the current revision of the motor by holding it in my hand and using an air compressor to spin it up until it reached a speed where the ESC could kick in - but I dropped it before I could see what it really could do. If you want to build this right, I recommend using 20 gauge magnet wire: https://www.amazon.com/Remington-Industries-22SNSP-Enameled-Diameter/dp/B01BD80T6M/ref=sr_1_6?crid=3N0QCNS8MFAQY&dchild=1&keywords=20+gauge+magnet+wire&qid=1587794470&sprefix=20+gauge+mag%2Caps%2C197&sr=8-6 These magnets: https://www.kjmagnetics.com/proddetail.asp?prod=BX082-N52 This glue: https://www.amazon.com/Bob-Smith-Insta-Cure-Super-Thin/dp/B001NI4JWI/ref=sr_1_3?crid=2SKDU5C37H0OK&dchild=1&keywords=cyanoacrylate+glue&qid=1587794640&sprefix=cyano%2Caps%2C229&sr=8-3 These bearings: https://www.amazon.com/PGN-R4-2RS-Sealed-Bearing-Lubricated/dp/B07GT739PV/ref=sr_1_4?dchild=1&keywords=1%2F4+id+bearing&qid=1587794654&sr=8-4 This screw: https://www.amazon.com/Stainless-Available-Socket-Button-Screws/dp/B079H5DP8X/ref=sr_1_15?crid=1Z2OBUYPDM7KP&dchild=1&keywords=1%2F4%2B20%2B3%2Binch%2Bbolt&qid=1587794703&sprefix=1%2F4%2B20%2B3%2Binch%2Caps%2C206&sr=8-15&th=1 and a 1/4-20 locking nut. This PLA for the stator (any PLA will work for the other parts): https://www.amazon.com/Proto-pasta-Composite-Iron-1-75mm-500g/dp/B00X8BQYPS/ref=sr_1_1?dchild=1&keywords=magnetic+pla&qid=1587794802&sr=8-1 and a lot of patience when winding (it took me five hours, and I was also watching Pirates of the Caribbean). Also, I haven't tested it, but this might work as an ESC: https://www.amazon.com/Brushless-Waterproof-Electronic-Speed-Controller/dp/B081C3RD2T/ref=sr_1_9?dchild=1&keywords=brushless+car+esc&qid=1587794851&sr=8-9 or something similar.