Exone end to end binder jetting service

Designer 3D Prints His Own Brushless Pulse Motor

INTAMSYS industrial 3d printing

Share this Article

Nathan Matthews, by day a web developer in California, has designed and built Delta Tower, Core XY, and Cartesian style 3D printers. While he says he’s currently working on a 2.8W, 245nm laser cutter and etcher, it’s his 3D printed brushless pulse motor that caught our attention.

brushless pulse motor 3d printed detail

He says he’s always wanted to build a motor, but it took until recently for him to acquire the tools and skills to make it happen with CAD and 3D printing.

Magnets are often placed on the rotating portion of home-built motors, and while brushless motors are typically 85-90% efficient, DC brush motors are only around 75-80% efficient. The difference in efficiency generally comesMatthew's CNC Router designdown to the total power used by the motor being turned into rotational force, and thereby, less energy is lost as heat.

Brushless DC electric motors are also often referred to as “electronically commutated motors.” They are synchronous motors powered by a DC electric source via an integrated inverter or switching power supply which produces an AC electric signal which in turn drives the motor.

The rotor part of a brushless motor is often what’s known as a permanent magnet synchronous motor, and they may be described as stepper motors, but stepper motor designs tend to be used for operations where they are frequently stopped with the rotor in a defined angular position.

“I got inspired after watching LaserSaber’s EZ spin motor videos thinking I could definitely do that,” he writes. “Turns out there aren’t official specs or build instructions. He has a few videos that, if you’re careful, you can use to catch the necessary details.”

Matthews design features five arms for the rotor with two magnets to each arm. All the magnets face ‘North,’ or outward. Ten coils alternate between ‘push’ and ‘pull’ mechanic, and he says the setup gave him “decent” results from a single AA battery.

The designer drew up the frame for his motor in SketchUp, and then 3D printed it in PLA using his own custom, CoreXY machine. He says the motor parts were printed with very sparse infill, and while he hasn’t yet posted his .stl files as he’s still considering changing the design for a next iteration, he does plan to share them at some point.BrushlessMotor

According to Matthews, it took him “a few hours” to wind up all the coils by hand – each one took approximately 300 turns – and they were all wound with a similar technique.

“It wasn’t so bad. The most annoying thing was trying to keep count and someone would call or break my concentration,” Matthews says. “I ended up weighing each one but I should have checked the resistance instead. I won’t lie: my brain drifted into dreams of the apocalypse and having to do this to make a generator and survive. I know that’s an absolutely indulgent thought, but it was kinda fun.”

Will you take on the task of 3D printing a brushless pulse motor like this one by Nathan Matthews? Let us know in the 3D Printed Brushless Pulse Motor forum thread on 3DPB.com.

Share this Article


Recent News

Rapid + TCT 2021: CEO Reichental on New Nexa3D Products and the 3D Printing Industry

Carbon Founder’s 3D Printed Vaccine Patch Could Increase Disease Immunity



Categories

3D Design

3D Printed Art

3D Printed Food

3D Printed Guns


You May Also Like

3D Printing News Briefs, September 21, 2021: 3D Printed COVID Test, Meatless Burgers, & More

In today’s 3D Printing News Briefs, some new 3D printed industry technology is being tested at Curtin Malaysia, and three partners are working to make vehicles more lightweight. Researchers have...

Featured

SmarTech Analysis: 3D Printing to Reach Historic Growth Levels, Following Strong H1 2021

In its latest quarterly report, SmarTech Analysis anticipates tremendous growth for the 3D printing industry after an already a successful first half of the year. In an analysis that was...

3D Printing Webinar and Event Roundup: September 12, 2021

Buckle your seatbelts, it’s going to be a busy week of webinars and events, both virtual and in-person! RAPID + TCT and FABTECH will both be held in-person this week...

3D Printing Webinar and Event Roundup: August 22, 2021

From food 3D printing and GE Additive’s Arcam EBM Spectra L 3D printer to 3D printing and CAD in a post-pandemic world and topology optimization, we’ve got a busy week...


Shop

View our broad assortment of in house and third party products.