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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Pimp My Cutting Fluid Pot

oil pot

Think about the simple tools you use every day. From writing implements to wire spoolers, there is arguably nothing that deserves to be hot rodded more than the things you depend on and might even take for granted.

For mad machinist [Chris], one of those everyday tools is his cutting fluid pot. Of course he already had one. A heavy one. A manly one. But it wasn’t completely ideal, and it wasn’t plated with gold that he prospected, refined, and processed himself. More on that in a minute.

[Chris] had obtained some neodymium ring magnets a while back. He was playing around with them in his shop when he noticed that his cutting fluid applicator brush fit nicely through the center and, being metal, was contained nicely through the wonders of magnetism. It was then that he decided to build a cutting fluid pot that would keep his brush in place and remain upright. Better living through magnetism.

He drilled and chamfered the brush hole out of a #20 JIC hydraulic cap and used the matching plug for the base. In case your catalog is out of reach, those are a 1¼” pair. [Chris] bored tiny pockets in the base for tiny magnets. After bathing both parts in delicious brake cleaner, he adhered all the magnets with LOCTITE®.

Okay, so, he’s done, right? No. Of course not. It did not surprise us to learn that [Chris] is also a miner, and not the 8-bit kind that hates creepers. Over the last two years, he prospected, refined, and other gold-related verbs using equipment he made himself. Just make the jump and watch the video before we give it all away. You’ll laugh, you’ll cry, you’ll be compelled to watch his other videos.

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Build a levitating bed for under $1000

Many of us have had this exact thought and wondered if it was feasible. As it turns out, you can, in fact, just buy a bunch of magnets and make a levitating bed. Those magnets need to be extremely strong, so [mememetatata] used some rather large Neodymium magnets. This frame involved some careful planning since these magnets can actually be quite dangerous if not handled properly. [mememetatata] did manage to get everything spaced correctly and now has a bed that can levitate holding up to about 250 lbs. We really want to know what it feels like. That kind of thing seems as though it would be difficult to describe.

As usual, more information might be available in the reddit thread.

[thanks poisomike87]!

Engineering with magnetic spheres

We would imagine these experiments were spawned by a devastatingly boring day at the office. [Sparr] found himself the proud owner of one thousand rare-earth magnets and decided to see what geometric shapes he could build with the spheres. These are gold-plated N35 Neodymium magnets that measure just 6mm across. He discovered that every structure is built from rings of magnets with shapes dependent upon what sequence of increasing or decreasing members are used. What he’s done is visually pleasing but we’d like to try it ourselves to see how resilient each structure ends up being.

[Sparr’s] post is from the Freeside Atlanta blog, a hacker space collective. [Curbob], a regular with the group, tipped us off that a few hacker conventions are coming up in their area and they’re looking for speakers for one-hour talks about projects. If you’re near Raleigh or Atlanta this is your chance to show off that ridiculously complicated project you’ve been risking your marriage to complete.