600 Watt, 3d-printed, Halbach Array, brushless DC electric Motor

  • 🎬 Video
  • ℹ️ Published 6 years ago

Overview of a 3d-printed brushless motor. Magnets in the rotor are arranged as Halbach array. Fully redesigned version based on the makeSEA motor. 600W, over 80% efficiency. Created with Fusion 360.

💬 Comments

Christoph, your work is beautiful. Not only is it well designed but beautifully documented. Thank you for raising the bar!

Author — Dan Royer


Christoph, I would just like to say thank you for sharing this impressive motor design, manufacture and assembly with us. It is great to see 3D printing being used in a practical dynamic application rather than just being used for printing vases, figurines and other silly objects.

You mentioned that the stators ferromagnetic material reduces the rotational speed while increasing the motors torque. Have you ever tried testing the motor using conventional stator materials (soft iron or aluminum)? It would be interesting to see how this effects torque and overall efficiency.

Author — Micheal Cairns


I've been looking for a long time for a homemade motor that is actually useful, and I finally found it. Stunning work, well done.

Author — Jer Schmidt


Naprosto úžasná konstrukce. Perfektní provedení.

Author — Jan Solovsky


Hi Chris, any insight on how the stator compares to stators made from stacked silicon rich steel sheets? I've read some literature about how the ferromagnetic filaments are not much better than normal plastics in terms of magnetic permeability and is not suited for this kind of application.

I'm interested in building high-torque direct drive motors for robotics applications.

Author — KrillNyeTheShrimpGuy


It's good to see simple effects utilized like in the Halbach-array configuration in practice! Keep it up!

Author — Oscar Campbell


Mr. Laimer, What a great example of engineering work you have posted. It will be a while before any one posts a 3D printed motor with this level of performance and engineering documentation. Thanks so much for your effort. -Warren

Author — warren reif


This is amazing work and amazing presentation of the development process. The 3D model of the winding for me was the most impressive!

Author — obpinkslip


That was impressive! How long did it take you to design, print, and put together the motor?

Author — Jason T. Rogers


this is really well done man. I can't wait to see what else people will come up with to push this tech forward.

Author — Javierm0n0


Amazing! I had no idea you could 3D print motor cores. How is the eddy current heating compared to a regular laminated core? Must not be too bad or it would soften and warp :)

Author — dekutree64


Nice video, thank you for that and for the experiment itself. I'm wondering what are the stress and temperature treshold of the plastic material you used. Could it be used for larger motors such as the ones used in cars ? (You know, no rust).

Author — Jonathan Brochu


Mate, I'm nowhere near ready to do this, but your work is exemplary and detailed to levels which can only be called fatherly love. A kW ... OMG ... I want one for each wheel on my scooter

Author — finophile


Wow--well done! This motor was my first thought when I saw your first MakeSEA motor. Looking forward to making my own when my printer arrives.

Author — R. Taylor Garlock


If you could 3d print a rotary encoder and a gear box Integrated into the casing, you could make a 3d printed servo motor, and with that, you could make a mostly 3d printed 3d printer...

that's a rabbit hole that is very tempting to leap into...

Edit: I've been waffling about getting a 3d printer for a long while now. Your video on this just made me decide to save up and get one.

Author — Hexx Bombastus


Christoph, you made me a believer in 3-D printing. Keep up the great work and have a great day too!!

Author — Victory First


That is a very interesting way to produce huge north spikes.
Love to see this in combo with Bedini circuitry to collect the collapsing field.

Author — Terminal Psychosis


Now its time to print one specifically for use as a dynamometer. That way you can keep track of how design changes effect efficiency. I bet it also wouldn't be too difficult to design a small rod with a self centering clamp on one side to test holding torque. it looked pretty strong when it was made to cog a the end of that one shot. Splendid work so far. If you could automate winding you could probably take an entire industry by surprise.

Author — Atlas Reburdened


Well done sir, such an amaizing and very impressive work and the 3d printed parts are really awesome.
I still have some questions:
does this method give a well balanced motor shaft or not?(because I realised that the fan is vibrating a little bit)
Could you tell me how much does it cost to build a motor like this one because I really want to build a BLDC one?

Author — Youssef SALIMI


Hello Christoph, I am an electrical engineering student and I have to admit that I would not have bet on a 3d printed motor before seeing your amazing work.
I wondered what is the model of your 3D printer, what are the pros and cons of it ? Thank you by advance !

Author — Quentin Loeuillet