3D Printed Halbach array Motor. 600W, over 80% efficiency!

Not satisfied with the specs of off-the-shelf brushless DC motors? Looking to up the difficulty level on your next quadcopter build? Or perhaps you just define “DIY” as rigorously as possible? If any of those are true, you might want to check out this hand-wound, 3D-printed brushless DC motor.

There might be another reason behind [Christoph Laimer]’s build — moar power! The BLDC he created looks more like a ceiling fan motor than something you’d see on a quad, and clocks in at a respectable 600 watts and 80% efficiency. The motor uses 3D-printed parts for the rotor, stator, and stator mount. The rotor is printed from PETG, while the stator uses magnetic PLA to increase the flux and handle the heat better. Neodymium magnets are slipped into slots in the rotor in a Halbach arrangement to increase the magnetic field inside the rotor. Balancing the weights and strengths of the magnets and winding the stator seem like tedious jobs, but [Cristoph] provides detailed instructions that should see you through these processes. The videos below shows an impressive test of the motor. Even limited to 8,000 rpm from its theoretical 15k max, it’s a bit scary.

(Dan Maloney - HackaDay.com)

But, How it works? 

This is the Halbach array setup. Every 5 magnets the pattern repeats. https://en.wikipedia.org/wiki/Halbach_array for more information.

Here is the explanation / assembly video

Alexandre Mainardi

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Comment by Andrew Rabbitt on May 28, 2017 at 2:31am

Takes a fair bit to crack the 90% efficiency mark for a BLDC motor.  Most are peaking shy of 85% and some a long way.

Impressive job though.  I suspect that 3D printed halbach array motors might have more use in gimbals - potentially as sector motors or as torque motors.

Comment by John Arne Birkeland on May 29, 2017 at 1:26am

Yeah, I was thinking the same. Integrating parts of the motor into the gimbal structure would be interesting.


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