A HUGE 3D Printed Brushless Motor??? How Much Thrust Can It Make?
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- เผยแพร่เมื่อ 7 ก.ค. 2022
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Hope you guys enjoyed the video! This thing was really fun to make and test. A bit scary too. Nevertheless, it was a cool project, and I would love to do more with the motor in the future. Let me know if you have any ideas.
@ChristophLaimer:
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Make a quadcopter with small 4 bldc 3d printed motors that would be amazing like this video. 👍
This size is fine, six of them and a nitro generator please. :)
Little did he know this would be done
@@ronnetgrazer362 please don’t fall for this guys scam
Spending time making cool swirl? Worth it! 10/10
100% Agree
Oh Hell yeah, SO worth the extra effort. Screw a cherry, man. That's like having a Carolina Reaper on top ;)
it changes direction 6 or 7 times😉
@@reyalPRON Assuming you're not joking, that's just what things look like when they spin super fast
@@tharnok5191 ahhh... geesus... what do u think?
Super cool build!
I'd be tempted to find a wire mesh sleeve or something that fits around the entire motor housing just to keep any larger chunks in place if it grenades itself. That thing is terrifying at speed
Carbon fiber tow is great for that sort of thing.
If you are genuinely worried about it breaking apart, then you shouldn't be using it. Go use a motor made of metal.
containment rings we use those when we are testing turbines and for the hydro boats.
@@deang5622 That's not the point...
In all seriousness, if you remove the infill material from the rotor section and fill a portion of it with ferrous material as close to the magnets as possible, you'll increase the torque a bit. Throw some steel wire or something.
I'd be really interested to see comparisons between magneti- and non-magnetic filament.
Compared to electrical steel the relative permeability of magnetic filament is awful, less than 1%. On the flip side it's up to 8 times better than air or non-ferrous filaments so I'd expect a significant reduction in torque with a non-ferrous core.
Very interesting idea!
I've been doing torture tests since getting my printer recently and have found thin stainless steel mesh goes a long way you could also put a few bands towards the center of the housing to help keep your walls from buckling like you see on water towers
I've always been interested if could hybridize 3D printing to add stuff like layering in wires or structural materials automatically as layers are put in I know can stop at steps and manually put stuff in
@@AsthmaQueen Mark forged does that with carbon fiber filament into nylon!
That was a really cool video! Very curious to see how reliable this motor is. Be really cool to see this on a drone. Kind of crazy how much thrust a piece of 3d printed plastic can really produce
I'm surprised it was balanced so well. Knowing the properties of PLA, you should not run it under severe loads that generate heat. Other then that well done and getting the windings correct at the first shot.
The bearing should isolate source, or do you mean from the electricity.. good thing it comes with a cooling fan
@@felurianmasters4369 no I'm referring to the induced magnetic field heating up the windings under load.
To my understanding the motor has built in cooling system, plus... I think that heat is the least of your concerns when you have a prop at the tip :)
My experience with PLA+ its very sturdy compared to PLA.
Wow!!!!! Amazing and huge thanks for your efforts!!!
Great way to test your layer adhesion
whoa, the motor mount is looking sketchy :D and the vibrations close after start are scary, but hey it worked haha. Nice. I tried to print things that spin only once. You can guess how it ended up.
Impressive and scary at the same time!
Great video, with graphs and all 👍👍😍
Thanks for sharing your experiences with all of us :-)
Man that was really awesome and i know how hard is to wind the copper and it's perfect 👍
That's impressive! I may try to print and make one of these.
Seems quite viable for a quadcopter. I think it may be a good idea to put a few layers of fiberglass around the outer motor to hold it together, and do some dynamic balancing to keep the vibrations to a dull roar.
Really nice. It would be interesting to see what kind of rc vehicle you could use it in!
Hello Michael i had a couple ideas for possible improvements, there is a couple ways i think this could be be helped. I would recomend trying to get it balanced even if its statically. IDk where you are but it would be fun to put this on our dynamic balance machine and see how much it is out. it being round its probably close but i wonder if the infil has biased this to a certain area. my ideas off the top of head would be to put the printed parts into a jar and pack it tightly with kinetic sand. then spin it up to around 900 rpm or so inside of a oven to aneal it while rotating. a cheap air drill could probably be used if its metal to workk ouut something that can take the heat. i se you have printed it with the layer lines xially around the body of the motor, i would like to see if some thing metal mesh could be installed on the outside of the motor body tieing the layer/grain structure together better. eitehr heat set it in or use some UV resin and instal it and dip it in resin and agin spin it during the cure. also i feel like you should look into getting some statorade its a ferro fluid that helps disipate heat. probably rambling also sorry for the spelling and grammer its not my strong point. great project and video tho dude cheers
that magnetic filament idea was genius, cool video!
In addition to what the others said about strengthening the print I'd like to add putting it in fine sand or some powder and chucking the parts in an oven to sinter it and improve the layer adhesion
Good luck mate
This was cool and honestly made me wonder a few things. Like if you were going to put this on something (say a model plane), how would you go about balancing the rotating components? I know there will always be some vibration, but I'm guessing at least some of it could be dialed out.
To strengthen it and prevent its expanding and exploding you could use hose clams on the outside, use 2 and put the bolt assembly on opposite side with each one to keep it in balance. Also a general case balancing would be good too. Maybe also print in nylon.
3 clamps to improve balance
Probs to giving the guy who made it the credit and the transparency
It's a cool project for sure
Sounds like a real plane and it's great
My eyes were glued to the layer lines the whole time on that last test lol! I'd for sure be a good distance away if I was there but it seemed to hold up great!
Cool project, nice build. Now 12S or bust!
Neat. I think balancing it would go a long way to improve performance.
Maybe a good idea to add some metal tape around the stator outside for extra strength and safety. Just in case of a crack it will prevent pieces flying around. I think it also looks cool because after applying it, it will look like a metal body.
There's lots of vibration so its probably affecting motors max performance. May be printing with SLA can fix most of them. I wonder how resin mixed with iron dust behave
It’s really cool! May I know how to get the thrust power value feedback, thank you very much!
That is cool to be able to do so much yourself
try it with copper filament may not work but aye worth a shot
How is it holding the heat? Is it enough with the propeler's wind to mantain the motor's temperature under a critical point which affect it's structure?
HAHA This popped up in my feed, Im just finishing printing a few sets of these parts for a buddy to build some up. Neat to see what its gonna look like.
rotating parts should be 100% infill usually, otherwise uneven distribution of weight and load bearing capacity can become issues. 0% infill with thick walls works in some builds.
You should make more of these and put them up for sale!
Cool I made a plastic casing motor about 8 years ago albeit without any 3D printing
Ever tried the pla+ from esun? Been seeing a lot of protopasta lately and may try it
Awesome test. I guess that an axial flux motor should perform better.
Do you know about axial motors? They are so simple to make, almost like they are made to be 3d printable
Me seeing your shadow in the background while the death rotors are spinning. Me in my blast proof bunker watching and sill being scared.
How about trying to fit some temperature sensors in the wires, and then ramping up the current to see where the limit of the motor actually lies? It might also be cool to modify the existing design to implement integrated forced air cooling.
A very impressive motor.
In order to avoid iron you can use the BLDC axial flux configuration, which has the additional advantage to offer the minimum of structural materials. I like the version where a single coil plate with mounting points sits between two rotating permanent magnet plates. This configuration gives the most torque. The rotating plates should be made of fiber-reinforced epoxy (G10) plate material, especially if you operate them at higher rotational speeds (200 to 500 rps).
You can have a look at such motors unter "How to make Brushless motor from clear acrylic" in the American Tech TH-cam channel.
Looks like there's a certain range of RPM to avoid, unless a bit can be done to balance it better. But not bad given everything else involved.
The windings looked like they were doubled? Isnt that usually done for more torque? Or for speed?
I would experiment with thinner wire for more windings. And thicker guage for more current and see which you prefer.
I'd be very interested to see Voltage / Current / RPM plotted alongside your Thrust graph.
Balancing. That could be one thing to do.
That is pretty slick! I would consider maybe at least PETG for heat tolerance. Those motors can get toasty.
Smaller motors are so cheap that I wouldn't want to put that much time into something I can get for $20-30. But for something big or custom build...sure.
Might be a little less crash resistant too. I've run some motors through dirt and hard ground, blew them out and flew again. Could see plastics breaking more easily. But hey.... fly, crash, repair and repeat. As long as the insides are still good...new print job and you're back up. Can't do that with standard motors.
In that case it would be best to use carbon fiber reinforced nylon filament. Nylon is one of the most heat resistant polymers available as filament, and the addittion of carbon fiber makes it considerably stronger, comparable to most stronger aluminium alloys.
@@pieterveenders9793 Yup. Was thinking Carbon black. Really tricky to print from what I've seen but once you get it tweeked...amazing material! Upgraded my printer to all metal hot end but...still locked into the firmware 260°. I gotta tweak the Marlin Firmware I have on there but... I just started with 3D printing and still having fun with PLA, PLA+ and PETG.
Funny thing is... my buddy had been trying to get me into this for a while but I didn't know what I would really print. Then, saw all kinds of stuff for RC Planes and the potential to design stuff with tinkercad. I've designed and printed like 2 parts for planes and dozens of other stuff LOL. That thing had been printer pretty much daily for first 4 months. Just finished up a dinosaur nightlight with WS8212 LEDs for my grandson. Came out really good. Crazy how much you can do with microcontrollers like ESP32 and 8266S. Lots of ideas for planes too since the are so small, lightweight and low voltage!
Nice project 👍 😃
if you leave holes in the rotor to put iron bars, does it increase efficiency? with normal plan
Does it count for magnets pulling together in gforce calculation?
What kind of rpm were you getting? Back in the 60’s I had trouble keeping windings on small Mubuchi motors that were rewound and running 10,000 rpm for slot cars.
Waterpump or power generator by water, Hooverboard? love this project :)
Nice now power something with it 😁👌
Dude, you should make a quadcopter drone with 4 of these and then see just how much weight you can lift with it. Imagine getting to the point where you could 3D print a single person flying craft!
How many watts did the motor draw with the big prop and 6s?
A motorized vehicle with this motor would be really cool! Maybe print 2 and use them on an electric longboard?
It looks like 600w 2 would definitely power longboard
@Flitetest please make a plane with some of these
One upside for propellers is that their wind can be used for cooling. Should heat be a problem.
That's pretty neat I may have to try this. But I am trying to use a 3 phase rc car motor in a fan. And can find a stand alone controller for the motor. The fan is a 10" dewalt fan lol
You need an Arduino, along with the Battery and ESC for the motor, throw in a cheap potentiometer and with some real simple code you can adjust the speed with the pot. (you can also add max/min speed etc) I built a surfboard with Lidar + Sonar for pre-mapping Talla Aquaduct in Scotland before Abyss solutions brought their $100k+ scanner from OZ, they didn't want to lose it in the tunnel. did the same job but mine cost about 30 bucks 🤔
Maybe, just maybe, it could be useful with liquid cooling circuit, and wrapped in carbon. Otherwise it either melts or flies into shrapnel eventually. It would be a much more practical approach to use laser cut special steel for an iron core, while keeping the 3d printed hallbach array.
Anyway, what is phase to phase resistance and no-load current?
Sounds like a Piper Meridian on take off roll.
Can you make a metal sleeve on a lathe just to slip on the outside ring of the motor. So centrifugal force is suspended if you get this. Just thinking a 1 mm thick sleeve would not add too much weight.
Hey, following Christophs instructions I wasn’t at all able to fit the windings into the stator. How did you do that?
Yeah his instructions on windings were a bit misleading. I used half the number of turns that he says to use
@@michaelrechtin Unfortunately my motor didn’t work with fewer windings. The project is abandoned now. Still have all the printed parts and everything. I assembled it completely but it never ran.
I then designed my own motor in CAD which did run very nice. If you’re interested I could send you the CAD files. :)
My motor is an inside rotor design tho
Would making it metal improve it all? Like if you used one of those metal 3d printing services?
Cool, sounds like a turboprop engine 😎
what if you use it as a generator? will this work and what power you can get out of it?
Would love to see 4 of those in a quadcopter! with 24kg! lol, looking forward to that!
That bldc body spin that mean if you creating longer tube of bldc body that bldc doesnt need shaft to mounting blade just put in the spining body the blade, in other mean bldc can use as turbine engine
will be interesting to see if it's indeed 600W capable
I suppose it's time to try for a 3d printed axial flux motos
If you could print with two different types of materials at the same time, could you print a ready to run motor?
I could watch that sweet swirl spin for hours
Looks great. Very exciting. I think I would balance everything before I pushed it harder. Looks like there is a little vibration in it and that could be a big issue if pushed too hard.
Interesting motor, i wonder if this motor could be scaled and power a electric vehicle, such as a motorcycle or a small car. And if so, how much hp could it give.
I just want to see a drone with 4 or 8 of these strapped to it XD
With a light airframe, that drone would be wild.
I want to try this out with my CF PEEK Printer.
It looks to me that you have the motor rotating counter clockwise and the propeller mounted to apply downward thrust. Was this to keep the rig from flying off of the mounts? Easer to measure thrust that way.
Yes! Makes sure that the structure underneath doesn’t affect the thrust data
fyi, if in the future you make another motor do NOT use those bearings with rubber seals, the seal gets hot and melts and you blow the bearing, get the metal shielded ones.
What kind of bearings are in that motor? You know the type of bearings in fidget spinners or ceramic bearings. If you found the right size and swapped them out wouldn't you get more RPMs and a quieter motor?
use a bigger prop to keep the rev under 5000 /min 20% under the tested rev. and keep the temp low because the plastic gets softer by the degree temp increase. good luck ery nice project.
Maybe you could wind some carbon fiber around the circumference? Like tesla did on the plaid motor! Then it won't be so sketchy to Rev it up high 😅
Whoa, cool...
It's your wife! can u meet me somewhere?
0:27 - It would explode using PLA, maybe carbon fiber filament would be stronger.
FPV drone pilot here and I can say that its awesome to see a 3d printed motor and on 6s that thing goes NUTS! Great job on the video too!
Impressive it didnt melt. My rc brushless motors can hit temps above 70C
Gotta balance that rotor on there!
Now you gotta build a VTOL
I may be a little biased…
👀👀
Just a thought, the magnetic filiment may induce heat losses due to eddy currents building up in the "housing" because of the non lamented nature. Maybe like mentined earlier do a non magnetic filiment test and compare, it would be interesting.
Metal particles in filament do not touch, so eddy losses will be negligible.
Could the motor be used to generate electricity like a wind turbine?
A long motor. using really long magnets instead lol (would it have more torque?)
Did it reach 18K RPM? I'm asking because I was like, when it seems to stop spinning and reverse, that's when the speed matches the FPS of the camera. And so I counted 5 slowdowns and a bit, which is more than 300 RPS or 18K RPM, assuming the camera is 60 FPS. I wonder if this estimation method works or not.
I was shooting at 120fps. Just in case it blew up
I imagine that kind of blec turbines product which can replace liquid fuel turbine long bldc that spin like 50.000 rpm+
Could you use this motor as a trolling motor for a Kayak?
Could this be adapted as a generator? Say wind or water?
Sure can.
It can for sure, the question is how efficient would it be and how powerful? I guess around 100W.
When the drone isn't flying, bigger blades clipped on turn it into a wind turbine to recharge its own batteries. Or your bike.
the lack of a true magnetic core means it doesn't reluctance cog as much, which is probably why its quieter. its also why its not very power dense unfortunately.
A quad copter drone would be cool.
There is *no way in hell* I'd spin that thing up without some sort of a blast shield between me and the motor!
How do you get 2k G's of acceleration with 30 seconds of ramp up time? There's no way that 3d plastic would survive that lateral force
10g magnet should way 21kg each, would it not?
That is so fucking cool. It really didn't seem like a very complicated design.
I'd love to see the outside part, that holds the magnets, wrapped in glass fiber and balanced with some epoxy to hold it together. 50 lbs of force on those magnets puts in the realm of pcp airguns. It's very dangerous.
Yes, please add fiberglass fabric or roving.
Interesting tonwatch. Was that an Alfawise U10 3d printer?
Aha Creality look alike. Lol…thanks
It’s coreless so up the voltage and decrease the current see the results then