Finding A Way To Produce Powerful Motors Without Rare Earths

January 13, 2026 by Lewin Day 35 Comments

The electric vehicle revolution has created market forces to drive all sorts of innovations. Battery technology has progressed at a rapid pace, and engineers have developed ways to charge vehicles at ever more breakneck rates. Similarly, electric motors have become more powerful and more compact, delivering greater performance than ever before.

In the latter case, while modern EV motors are very capable things, they’re also reliant on materials that are increasingly hard to come by. Most specifically, it’s the rare earth materials that make their magnets so good. The vast majority of these minerals come from China, with trade woes and geopolitics making it difficult to get them at any sort of reasonable price. Thus has sprung up a new market force, pushing engineers to search for new ways to make their motors compact, efficient, and powerful.

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All Projections Suck, So Play Risk On A Globe Instead

December 30, 2025 by Tyler August 11 Comments

The worst thing about the getting people together is when everyone starts fighting over their favourite map projection– maybe you like the Watterman Butterfly, but your cousin really digs Gall-Peters, and that one Uncle who insists on defending Mercator after a couple of beers. Over on Instructables [madkins9] has an answer to that problem that will still let you play a rousing game of Risk– which will surely not drag on into the night and cause further drama– skip the projection, and put the game on a globe.

The pieces are from a 1960s version. The abstract tokens have a certain charm the modern ones lack.

Most globes, being cardboard, aren’t amenable to having game pieces cling to them. [madkins9] thus fabricates a steel globe from a pair of pre-purchased hemispheres. Magnets firmly affixed to the bases of all game pieces allow them to stick firmly to the spherical play surface. In a “learn from my mistakes” moment, [madkins] suggests that if you use two pre-made hemispheres, as he did, you make sure they balance before welding and painting them.

While those of us with less artistic flair might be tempted to try something like a giant eggbot, [madkins] was able to transfer the Risk world map onto his globe by hand. Many coats of urethane mean it should be well protected from the clicking or sliding magnet pieces, no matter how long the game lasts. In another teachable moment, he suggests not using that sealer over sharpie. Good to know.

Once gameplay is finished, the wooden globe stand doubles as a handsome base to hold all the cards and pieces until the next time you want to end friendships over imaginary world domination. Perhaps try a friendly game of Settlers of Catan instead.

Trace Line Clock Does It With Magnets

December 8, 2025 by Donald Papp 9 Comments

We love a good clock project, and [byeh_ in] has one with a design concept we don’t believe we have seen before. The Trace Line Clock has smooth lines and a clean presentation, with no sockets or visible mechanical fixtures.

Reading the clock is quite straightforward once one knows what is going on. At its heart, the unmarked face is much like any other analog clock face, and on the inside is a pretty normal clock movement. The inner recessed track on the face represents hours, and the outer is minutes. The blue line connects the two, drawing a constantly changing line.

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Measurement Is Science

June 21, 2025 by Elliot Williams 22 Comments

I was watching Ben Krasnow making iron nitride permanent magnets and was struck by the fact that about half of the video was about making a magnetometer – a device for measuring and characterizing the magnet that he’d just made. This is really the difference between doing science and just messing around: if you want to test or improve on a procedure, you have to be able to measure how well it works.

When he puts his home-made magnet into the device, Ben finds out that he’s made a basically mediocre magnet, compared with samples out of his amply stocked magnet drawer. But that’s a great first data point, and more importantly, the magnetometer build gives him a way of gauging future improvements.

Of course there’s a time and a place for “good enough is good enough”, and you can easily spend more time building the measurement apparatus for a particular project than simply running the experiment, but that’s not science. Have you ever gone down the measurement rabbit hole, spending more time validating or characterizing the effect than you do on producing it in the first place?

Iron Nitride Permanent Magnets Made With DIY Ball Mill

June 19, 2025 by Maya Posch 10 Comments

Creating strong permanent magnets without using so-called rare earth elements is an ongoing topic of research. An interesting contestant here are iron nitride magnets (α”-Fe₁₆N₂), which have the potential to create permanents magnets on-par with with neodymium (Nd₂Fe₁₄B) magnets. The challenging aspect with Fe-N magnets is their manufacturing, with recently [Ben Krasnow] giving it a shot over at the [Applied Science] YouTube channel following the method in a 2016 scientific paper by [Yanfeng Jiang] et al. in Advanced Engineering Materials.

This approach uses a ball mill (like [Ben]’s planetary version) with ammonium nitrate (NH₄NO₃) as the nitrogen source along with iron. After many hours of milling a significant part of the material is expected to have taken on the α”-Fe₁₆N₂phase, after which shock compaction is applied to create a bulk magnet. After the ball mill grinding, [Ben] used a kiln at 200°C for a day to fix the desired phase. Instead of shock compaction, casting in epoxy was used as alternative.

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Diagram showing the structure of the base.

Magic On Your Desk Via MagLev Toy

May 7, 2025 by Tyler August 9 Comments

Magnets aren’t magic, but sometimes you can do things with them to fool the uninitiated — like levitating. [Jonathan Lock] does that with his new maglev desk toy, that looks like at least a level 2 enchantment.

This levitator is USB-powered, and typically draws 1 W to 3 W to levitate masses between 10 g and 500 g. The base can provide 3 V to 5 V inductive power to the levitator to the tune of 10 mA to 50 mA, which is enough for some interesting possibilities, starting with the lights and motors [Jonathan] has tried.

In construction it is much like the commercial units you’ve seen: four permanent magnets that repel another magnet in the levitator. Since such an arrangement is about as stable as balancing a basketball on a piece of spaghetti, the permanent magnets are wrapped in control coils that pull the levitator back to the center on a 1 kHz loop. This is accomplished by way of a hall sensor and an STM32 microcontroller running a PID loop. The custom PCB also has an onboard ESP32, but it’s used as a very overpowered USB/UART converter to talk to the STM32 for tuning in the current firmware.

If you think one of these would be nice to have on your desk, check it out on [Jonathan]’s GitLab. It’s all there, from a detailed build guide (with easy-to-follow animated GIF instructions) to CAD files and firmware. Kudos to [Jonathan] for the quality write-up; sometimes documenting is the hardest part of a project, and it’s worth acknowledging that as well as the technical aspects.

We’ve written about magnetic levitation before, but it doesn’t always go as well as this project. Other times, it very much does. There are also other ways to accomplish the same feat, some of which can lift quite a bit more.

DIY Linear Tubular Motor Does Precise Slides

March 31, 2025 by Donald Papp 25 Comments

We’ve seen plenty of motor projects, but [Jeremy]’s DIY Tubular Linear Motor is a really neat variety of stepper motor in a format we certainly don’t see every day. It started as a design experiment in making a DIY reduced noise, gearless actuator and you can see the result here.

Here’s how it works: the cylindrical section contains permanent magnets, and it slides back and forth through the center of a row of coils depending on how those coils are energized. In a way, it’s what one would get by unrolling a typical rotary stepper motor. The result is a gearless (and very quiet) linear actuator that controls like a stepper motor.

While a tubular linear motor is at its heart a pretty straightforward concept, [Jeremy] found very little information on how to actually go about making one from scratch. [Jeremy] acknowledges he’s no expert when it comes to motor design or assembly, but he didn’t let that stop him from iterating on the concept (which included figuring out optimal coil design and magnet spacing and orientation) until he was satisfied. We love to see this kind of learning process centered around exploring an idea.

We’ve seen DIY linear motors embedded in PCBs and even seen them pressed into service as model train tracks, but this is the first time we can recall seeing a tubular format.

Watch it in action in the short video embedded below, and dive into the project log that describes how it works for added detail.

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