Mounting a motor on a PCB is nothing new, right? But how about making the PCB itself part of the motor? That’s what [Carl Bugeja] has done with his brushless DC motor in a PCB project, and we think it’s pretty cool.
Details on [Carl]’s Hackaday.io page are a bit sparse at this point, but we’ve been in contact with him and he filled us in a little. The PCB contains the stator of the BLDC and acts as a mechanical support for the rotor’s bearing. There are six spiral coils etched into the PCB, each with about 40 turns. The coils are distributed around the axis; connected in a wye configuration, they drive a 3D-printed rotor that has four magnets pressed into it. You can see a brief test in the video below; it seems to suffer from a little axial wobble due to the single bearing, but that could be handled with a hat board supporting an upper bearing.
We see a lot of potential in this design. [Carl] mentions that the lack of cores in the coil limit it to low-torque applications, but it seems feasible to bore out the center of the coils and press-fit a ferrite slug. Adding SMD Hall sensors to the board for feedback would be feasible, too — in fact, an entire ESC and motor on one PCB could be possible as well. [Carl] has promised to keep the project page updated, and we’re looking forward to more on this one.
For a more traditional approach to printed motors, check out this giant 3D-printed BLDC.