Drum Motor/ Generator Stator Mold (Outrunner)

thingiverse

This is a design for a 6.7" diameter Drum Motor (BLDC) stator mold that offers an effective alternative to silicone steel or metglas/ceramic type stators, ideal for home inventors and builders. Follow the same directions as posted for this Thing: https://www.thingiverse.com/thing:2423846. This particular design is tailored for an outrunner instead of a inrunner motor and has been scaled down to be more compact. The resulting stator should measure approximately one inch thick. All other details required to complete the motor are left up to you, the builder. To achieve parts that can be reused, printing with 1.2mm walls, .8mm top and bottom layers, 30% infill, and .2mm layers is recommended. Good luck and have fun! Disclaimer: No formal scientific tests have been conducted. Operate and experiment at your own risk. Failure of parts spinning at high speed can cause damage to property, injury, or even death. Materials List: You will need a piece of board measuring 9" X 9" to serve as the mounting surface for this project, along with six 6-32 X 1" bolts to secure it in place. Masking tape should be applied to coat the interior areas, and a release agent such as Vaseline petroleum jelly should be lightly coated over the masking tape. A tipped applicator is necessary to apply the two-part epoxy, and a small funnel will come in handy for filling the mold with coated #8 soft steel shotshell pellets. For further details on these materials and the process, please refer to the YouTube videos provided at https://www.thingiverse.com/thing:2423846. A video explaining the process of steel shot preparation and giving credit to those who originally came up with the idea to use coated steel shot is available here: https://www.youtube.com/watch?v=kpHEyzvc4dY Smaller stencil parts were added on June 10, 2018, at 5:32 EST. A simple tool has been designed to assist with removing the stator from the mold. This tool can be used in conjunction with a vise grip or press to gently squeeze out the stator. Be patient and work your way around the piece, moving it out a little at a time.