Halbach Array Linear Direct 3D Printer Extruder Drive

myminifactory

I've been working with my Pusa I3 and almost all 3D printers use an extruder with a stepper motor, but I wanted to create something lighter using a 3-phase linear actuator with a magnetic Halbach array. The result is a direct replacement for NEMA17 in any 3D printer that's designed to deliver high performance. One thing I considered was using VCA as a drive, but it's just too expensive and not as powerful as the 3-phase coils and magnetic Halbach array combination. You can see my design in action on this video: https://youtu.be/aeM0KQuF120 Here are some key features of this extruder drive: * High force-to-weight ratio * Continuous and peak forces that can handle any load * Weighs just 4.2oz (119 grams) * Can accelerate quickly with its Halbach Array magnetic system and Scotch Yoke mechanism * For a full description, check out my Instructables page: http://www.instructables.com/id/Linear-Direct-3D-Printer-Extruder-Drive-Fusion-360/ To build this drive, you'll need five Neodymium Rare Earth magnets (5X5X25mm N42) or compound magnets - ten pieces will do the trick. You can get them from Indigo Instruments: https://www.indigoinstruments.com/ Keep in mind that changing the wire diameter will increase the force, but also boost the current consumption. I've tested this drive with a 3-phase bridge driver and it's more than capable of handling an extruder load. This is still an experimental device, though - my work on it continues.