MK3?
This is still a work in progress!
This is a project that I have been working on for a bit. it's a fully 3D printed dual rotor air core brushless motor.
The rotors are each 48 N52 Neodymium magnets oriented in a halbach array for 24 poles each. Each magnet was epoxied into place.
The stator is a winding pattern that I modeled, which uses 3 phases with 12 poles each for a total of 36 poles. The wire is 20 strands of 32 AWG litz wire that I wound. There are 4 turns per pole.
There are two bearings keeping the stator in line, with about 1mm of air gap between the stator and rotor. The one rotor half has heat set inserts which I used M3 screws to hold the rotors together. (though the magnets do a pretty good job on their own). Fully assembled the motor weighs in at 400g and is 22mm thick with a diameter of 120mm.
In this run I used a cheap hobbyist PWM ESC. and with a 4s lipo battery. The motor achieved a peak power output of 512 W (16v @ 32 Amp) @ 3500RPM. The load was a 20" propeller (not 3D printed).
in another test I ran it at 100W load for 10 minutes continuously and it survived, the temperature was 38C after. Also in this video you can hear a ticking at the end. This was due to a magnet coming loose and dragging against the stator as it spun. I believe this is thermally limited at the moment, but I also feel that there are more improvements to be made before attempting a metal print, machining.
Follow the Journey!
endless-sphere...
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