HOW IT WORKS
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600W motor requires a little more winding for a lot more power.
Assemble all your tools and supplies before attempting to complete the build of the motor.
Halbach motor design requires 2 sizes of magnets.
This first iteration of the brushless motor led to many changes. 3D Printing is changing the world.
The 3D printed parts to the brushless motor make a colorful collage! See for yourself what these parts represent.
Assembling all the 3D printed parts and electronics for the windpowerWriter.
We’re busy printing parts for the high school science project utilizing the 3D printed brushless motor. We believe 3D printing in education fosters creativity and independent thinking.
The winding tool is a 3D printed part that make the brushless motor assembly easier.
A completed solar water distiller tile.
RC plane utilizing propeller design and 3D printed brushless motor.
A variation on the 3D printed propeller design.
This 3D printed coupler is tested as part of the water turbine project.
RC Plane testing 3D printed propellers.
The Pelton Wheel used in the water turbine project.
3D printed links for holding together the “tiles” for the solar water distiller.
The Pelton Wheel, as shown in this diagram, is part of the water turbine project under development.
Watch Christoph Laimer's page for the project files to create this award winning piece, the Tourbillon Watch.
Another Christoph Laimer project - watch for the files for this mechanical clock available soon.
The windpowerWriter in action. Part of the fun with this project is programming the arduino to write your own personal message.
Cut-away of the housing unit for the windpowerWriter showing placement of the internal parts.
The windpowerWriter consists of many 3d-printed parts, as shown in this diagram.
LEDs, which will be controlled by the programmed Arduino, are tested for the windpowerWriter.
A final 3D Printed WindpowerWriter. Join makeSEA and download the files to create your own version.
Connecting the Arduino that controls the LEDs in the windpowerWriter.
Find the print files for spatulas of all shapes and sizes in the Library of Useful Objects.
Mounting the makesea motor in the windpowerWriter.
LEDs, controlled by the programmed Arduino are inserted in the blades of the windpowerWriter.
Cable ties of all sizes are part of the Library of Useful Objects.
Check out the Snap Fit Clips available in the Library of Useful Objects and download the files when you join makeSEA.
Fitting the electronics into the windpowerWriter.
All the parts to the windpowerWriter are ready for assembly. Join makeSEA to access the files.
This one piece box with a flexible hinge is another of the pieces found in the Library of Useful Objects.
Jars with screw on lids - whoever has enough? Print these out in all shapes and sizes.
Find out how to select the magnets for the brushless motor.
A rotor with 2mm magnets was used in the testing.
The magnet is firmly fixed on the ground.
A permanent magnet is fixed on the lever above the coil.
Measuring, ranking and comparing the magnets before selecting.
Measure the basic characteristics of the motor by using it as a generator.
The goal of this project is 3D-printing a fully functional Wind Turbine at small scale.
The stator height is still 20mm in order to reuse the existing rotor with the 2mm magnets.
I’m using a scope to measure the RPM and the voltage.
The main housing needs to have space for a generator (same size as the 3d-printed brushless motor).
The first iteration of the brushless motor.
3D Printed Components of the wind turbine project.
Propeller shaft will have 5mm diameter and 2 ball bearings, and the generator is mounted coaxial with the propeller shaft.
The size of the objects is at the maximum of the build volume for an Ultimaker 2.
In the beginning I bought conductive and magnetic PLA from Proto Pasta.
3D Printed Brushless Motor consists of 4 main printed parts.
3D Printed Brushless Motor requires some additional non-printed pieces.
3D Printed Brushless Motor, Rotor: Use Magnets PETG or ABS.
3D Printed Brushless Motor, Motor Winding Tool - wires can be taped to the handle or tucked inside.
3D Printed Brushless Motor, Stator Winding Core.
Torque increases almost perfectly with the square of the speed.
Torque is more of a challenge, but with some physics, math, and a construction with a 20cm long lever and a scale measuring at a resolution of 0.1 g, it can be calculated.
All of the experiments performed to get familiar with conductive PLA.
I installed a hair dryer and heated it until the main block was feeling really hot.
The result when I was using the Makerbot Slicer with default PLA values and the magnetic PLA from Proto Pasta.
Finally, I reduced the temperature to 210° and I’m very satisfied with the final result.
The filament looked normal. It only had a small bulge between the cold and the hot part.
The cleaner box can be removed and added to a filament without unloading the filament from the extruder.
Aluminum foil was used for better contact.
The design is a single connected wire with various shapes.
It was quite a challenge to find good slicer settings for getting this printed.
While the result got better with each printing iteration, all of a sudden the magnetic PLA stopped printing.