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YouTuber Christoph Laimer has built this very powerful, 3D-printed brushless DC electric motor. It has 600 Watts, and performs with more than 80% efficiency.
The main components, such as the rotor and stator can be printed with a common FDM-printer. All magnets, copper wire, and ball-bearings used are ordinary components.
The magnets of the rotor are arranged as Halbach Array and the motor runs with a standard ESC widely used in different RC-applications (plane, drone, car etc).
OverviewÂ
Building InstructionsÂ
Assembly AnimationÂ
Update, Tuning and Testing
Useful LinksÂ
Step-by-Step Instructions: https://www.instructables.com/id/600-Watt-3d-printed-Halbach-Array-Brushless-DC-Ele/Â
3D-Files: https://www.makesea.com/makesea/1gt
Measurements: https://drive.google.com/file/d/0B_lTMVnODM_XTGtVVHNzaFBKem8/
Testing the original design (to explosion)Â
Christoph's original 3D printed brushless motor design can be found at http://www.makesea.com/brushless-motor.
In the below video he tested the maximum rotation speed, with the eventual destruction of the motor intended, to discover the safe operating range.