3D Printed Axial Flux Motor

3D printed toroidally wound axial flux permanent magnet air core motor.

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This is an ongoing project.

I am attempting to make a useful and accessible motor using cheap, widely available parts and utilizing 3D printing where it makes sense. Currently I am on my 8th version. The current version is an out runner style brushless motor with a single stator a two rotors.

The stator is three phases in a type of serpentine coil pattern. There is no ferrous core resulting in no cogging and no core losses. The wound stator is pressed and potted in epoxy and mechanically fastened to the hub.

The rotors each contain a halbach array of N52/N50 magnets stuck to an laser cut iron backing that is epoxied into the 3D printed halves.

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robertcharles5828 wrote 06/05/2023 at 08:37 point

I am currently working on my 8th version of a cheap and accessible motor utilizing 3D printing. It features an out runner style brushless design with a single stator and two rotors. The stator has a serpentine coil pattern, and there are no cogging or core losses due to the absence of a ferrous core. The rotors have halbach arrays of N52/N50 magnets attached to laser cut iron backings, which are epoxied into the 3D printed halves. For more details, you can visit my project on the <a href="">CNA website</a>.

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Nathann wrote 06/18/2022 at 17:18 point

does it work as a generator ? efficiency ? (power is around 300W from what i saw ?)

what is the price to build one ?

how hard would it be to make one that reuse magnet from old Hard drive ?

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William wrote 12/30/2022 at 18:25 point

Since this motor uses permanent magnets, you could use it for generation instead. However, this project is focused on it as a motor and wouldn't be optimized for power generation. That being said, if you wanted to do regenerative breaking for example, this is a bldc motor in an axial format.

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