1Print the STL-files
We used 3 perimeters of 0,7mm, but more perimeters equalling 2mm wall thickness should also work. Make sure you are accustomed printing larges pieces as these warp and loosen from the bed easily. A heated chamber made from cardboard helped us raising the temperature to 30-35°C.
- Speed: 60mm/s
- Rafts: Doesn't Matter
- Supports: Yes
- Resolution: 0.15mm
- Infill: 8%
- Filament material: PLA
- Filament_brand: Anything cheap
2Make some glue
Dissolve ~150g scrap PLA in 300ml DCM to create a gap filling glue that will chemically weld the parts together. Let it sit for 24h to dissolve properly.
3Weld all blade parts together
Stack the 5 pieces that make up the blade on top of each other and add DCM-glue in between. Firmly pressing both parts together after you applied the glue. Be careful that they line up properly!
4Glue the generator parts together
Add glue to each part and press everything together firmly for half a minute. That should be enough to hold everything in place.
Warning! Only glue the top 4 parts together, and the bottom 4 parts. Don't add top and bottom together yet because the stator has to be fitted in between.
5Build a tool to wind coils
A coil winder can be made from leftover scraps of wood and bolts. Make life easy and print coilwinder.stl so you have the perfect coil core.
6Wind the first coil
After you have turned 90 times, put some glue on the outside to prevent unwinding of the coil.
7Carefully take the coils out from the coil winder
Repeat this and the previous step until you have 9 identical coils.
8Set-up the mould
Print mould.stl 4 times and glue them together with the DCM-glue from the previous steps. After that, grease the mould and fit all 9 coils in it on a equal distance from eachother and with the same side up (all turning in the same direction).
9Fill the mould with resin
Pour the polyester resin in the mould until it is full and clamp a thick piece of plywood on top so it doesn’t fold. Remember, we want to keep the stator as thin as possible!
10Remove the lid
Let the mould sit for 24h, after that it can be opened again.