3D-Printed Halbach Motor Part Two: Tuning, Testing

Building your own Halbach-effect brushless DC motor is one thing. Making sure it won’t blow up in your face another matter, and watching how [Christoph Laimer] puts his motor to the test is instructive.

You’ll remember [Christoph]’s giant 3D-printed BLDC motor from a recent post where he gave the motor a quick test spin. That the motor held together under load despite not being balanced is a testament to the quality of his design and the quality of the prints. But not wishing to tempt fate, and having made a few design changes, [Christoph] wisely chose to perform a static balancing of the rotor. He also made some basic but careful measurements of the motor’s parameters, including the velocity constant (Kv) using an electric drill, voltmeter, and tachometer, and the torque using a 3D-printed lever arm and a kitchen scale. All his numbers led him to an overall efficiency of 80%, which is impressive.

[Christoph] is shipping his tested BLDC off to the folks at FliteTest, where he hopes they put it to good use. They probably will — although they might ask for three more for a helicarrier.

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Powerful, Professional Brushless Motor from 3D-Printed Parts

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.

Looking for a more educational that practical BLDC build? Try one cobbled from PVC pipes, or even this see-through scrap-bin BLDC.

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