600 Watt, 3d-printed, Halbach Array, Brushless DC Electric Motor [video]
We really need a cheap online laser cutting magnetic metal lamination service. There are more and more online laser cutting services, but they don't stock magnetic lamination steel. The only online specialized service is incredibly expensive.
We are in a golden age of electric motors, but access to custom laminations is a limiting factor for tinkerers (now that the magnet are widely available).
If used for anything substantial, such as an ebike that goes fast or up slight grades, this motor would simply melt. Its really cool though. A lot of ebikers fool around with liquid cooling but ive never seen it pulled off. This guy could take advantage of the 3d printing method to add liquid cooling and besides being really cool it might allow the motor to do useful work without melting.
The content-vs-time density for this video is extremely high and it was a pleasure to watch all of the video. I print in PLA rather than ABS right now so the video isn't directly applicable to my life but it's nice to see somebody working on the designs. Cheers to the author!
The enclosure looks like it's leaving a lot on the table in terms of cooling channels and structure. Given the printing can do all kinds of shapes it looks like it's replicated the kind of body that would come out of a mill or mold.
Are there any printers that can put down glass fibre in the process?
That's a nice project. The author claims 80% efficiency, which is reasonably good. Most amateur motor designs are far worse.
The plastic motor shell has a very smooth finish, and screw threads. What process did he use to 3D print those fine screw threads? I didn't think any available 3D printing process was good enough for that.
This is very impressive, but keeps me wondering - how is this engine better than the stuff you can just go and buy in the shop? This is an honest question, I have no clue what are the benefits here (besides obvious coolness factor!).
What's the type of paper called that he puts on the motor at the 2:15 mark? Doesn't look like simple iron dust.
So in brushless motor the outside part with the magnets is the part that rotates? is that way it's brushless? You don't need to supply electrify to the part that moves?
Or do I have this all wrong?
Impressive on so many fronts, it's so cool what's possible nowadays with modern prototyping tech. Thanks for sharing!
I hate the trend that's been going on for a few years now where they try to imply that all of a given product is 3D printed.
For example this motor is easily 80% metal and copper wire for the poles. The remaining 20% is the plastic case. That is the 3D printed part. Not exactly very impressive.