3D printed axial brushless motor for drones : one rotor & two stators

Two stators & one rotor axial flux drone motor realization in Laplace Laboratory (Toulouse France).
PhD thesis funded by Région Occitanie.
Research on axial flux motors in partnership whith Santa Catarina University (Brazil) in the project CAPES-COFECUB n°ph930/19.

[@harribeydom]

Actually we are doing some tests and compare it with a trapezoidal magnets rotor to prepare an article for a scientific journal. then we will try a new motor with 3D printed coils. Then we will share the design.

[@Tore_Lund]

Is the model airplane motor controller only for testing? A proper sinosudial inverter would yield higher efficiency and less heating. Because of the low induction of this type of motor, I2R losses are high when They are just run with a semi 3 phase waveform.

[@852derek852]

Great work. Out of curiosity why didn't you use delta configuration?

[@originalmianos]

@@Tore_Lund I agree, a mini VESC with FOC would be great.

[@moses5407]

Are the design files available now?

[@kingmasterlord]

it's a lot easier to wind your own coils than I thought. this opens up much larger possibilities

[@jakegarrett8109]

Typical motors are probably even easier, but time consuming and you just have to pay attention to directions. I think I would prefer the conventional way, also lower resistance and less soldering.

[@kingofthekoopas8857]

It’s one of those tasks that seems much harder than people think, to the point most don’t even try. It’s very possible to make brushless motors yourself

[@adrasx6999]

They are cheating and use a winding counter and thick wires. Coils can quickly become a huge pain in the bottoms to make at high quality with high turn counts. But yeah, you're right. I already 3d printed my own customizable motor test platform as well. 1 or 2 skateboard bearing, some 1.5-2mm copper wire, a 3d printer and off you go.

[@JohnnyKarate44]

Now THIS is PODRACING!!!!!!! Amazing!!

[@dividingbyzerofpv6748]

Looking forward to you stacking these in an arrangement like the multiple rotor cells of a Wankle engine. If you can cross the poles from one side to another side of the stator, why not throw another stator and another set of poles in there. Really cool way of building the motor.

[@Blox117]

nah screw that, make it an axial-radial flux motor. most torque ever

[@potatosalad68]

@@Blox117 yeah, and throw a nuclear reactor in there too

[@freddyfingerz9854]

I like your work and close to this would be great yes. How to contact?

[@pedmanga2]

2 brasileiros hein que orgulho!!!

[@mohankonduskar195]

2 brasileiros que orgulho!!

[@MarcosAurelio-nm7ei]

Dois professores brasileiros... Que orgulho, pena nosso país ser da forma que é.

[@prerupa]

é mesmo!

[@urano1988]

If I was your thesis opponent I would argue that without having the ferromagnetic yoke filling the inside of the coils so much flux is wasted. Note that there are iron-loaded filaments if you want to experiment without having access to some metal workshop, although lamination is crucial to limit losses. For that size, you need to push the continuous power up by a factor of 10 to make it interesting.

[@Blox117]

but what if you made a combo axial-radial flux motor?

[@mmsti7867]

Could you please share some links from where I can understand it's working principle and construction

[@steveblayer342]

Thats what i call engineering , any layouts and mesurments to build such powerful brushless motor ?

[@microflite]

Beautifully designed and executed!

[@noutram1000]

Hi, this is the sort of 'sleeves up' engineering to get excited about when you think of all the future possibilities of the axial flux design in EVs and eVTOL/Aircraft, well done! Have you looked into the relative merits of having a single coil layer in the centre and dual ring of permanent magnets? Also what about filling the magnet core -why coreless?

[@TheDIYer]

very nice love it ,looks like theres some pure engineering in it

[@josephowens4654]

Was there a design constraint for single stator? I would think power density would be much greater for dual stators in Halbach array. But in any case, great job!

[@freddieparrydrums]

True

[@markman1276]

Hi

[@Blox117]

probably, i mean hes doing it by hand

[@likewisepro]

Would you mind making videos explaining the concepts and procedures? I would like to know if it is possible to cnc the pieces and which materials would be appropriate. This is amazing and really good content.

[@jamescook6633]

Now you should make them into modules so that you can bolt multiple motors together For more torque. Good work super Cool!!!!!

[@brlinf06398]

too much torque, gearbox will take care of it

[@party4keeps28]

Awesome! Great shop too.

[@eydanvladislav599]

Que buen motor, dos estatores, trifásico, y un torque muy alto y altísimas rpm. Felicitaciones y gracias por conpartir.

[@3deeguy]

Twin stators, an excellent idea.

[@mukulwadhokar1192]

it actually gave me goosebumps ,

[@nickkantouros8809]

That's pretty damb amazing! Nice job man!

[@rolflerch5031]

Great work. I would also like to build such an engine. Is there a building instruction for it?

[@HiteshMistry0]

Would you mind if I could get the 3D printing model file, please?

[@djquestionthis]

It's beautiful as well as functional, bravo!!!

[@skippythemagnificent8103]

Lol, I remember a school visit to a GEC factory in the early 1980's (used to be a household name) and one building was full of people coil winding, day in day out (some for 30 years).It was all very sociable. The building was the size of at least three football fields. It gave me all the incentive I needed to push my interest in programming back then🙂

[@steveflor9942]

Really cool stuff.... Where is the position sensor..??? 3 phase ac sychronous motors use?

[@johnsanchez5414]

Brilliant work, what's the music by the way?

[@gkdresden]

In industrial developments the 2 rotors & 1 stator version seems to be more efficient because the magnetic flux goes more straight between two opposed permanent magnets, which results in higher magnetic flux for considerably shorter magnets. It is also possible to increase the magnetic flux further by use of an iron ring plate at the opposite side of the permanent magnets to the coils as a magnetic flux guide between each pair of permanant magnets.

[@adamrobertson7215]

Definitely easier to assemble :-). Looks like they might have tried the ring plate in the last test, seems it was of benefit here as well.

[@matinsakr6548]

Super travail. C est formidable

[@عمرومجدى-ي4ث]

جزاكم الله خيرا اخي الكريم وبارك الله فيك وهداك

[@solosailorsv8065]

GREAT !! How does this design approach compare to MAGNAX ?

[@federicosagun4615]

Clever. All you need now is the miniature version.

[@1islam1]

🔴 What Is Islam? ⚠️ 🔴 Islam is not just another religion. 🔵 It is the same message preached by Moses, Jesus and Abraham. 🔴 Islam literally means ‘submission to God’ and it teaches us to have a direct relationship with God. 🔵 It reminds us that since God created us, no one should be worshipped except God alone. 🔴 It also teaches that God is nothing like a human being or like anything that we can imagine. 🌍 The concept of God is summarized in the Quran as: 📖 { “Say, He is God, the One. God, the Absolute. He does not give birth, nor was He born, and there is nothing like Him.”} (Quran 112:1-4)[4] 📚 🔴 Becoming a Muslim is not turning your back to Jesus. 🔵 Rather it’s going back to the original teachings of Jesus and obeying him.

[@lorriecarrel9962]

I love diy in this category

[@eslanek785]

Why are there no magnets on both sides?

[@simonl7784]

all the care and love and prime materials and meticulous finish then @ 5:00 you go and solder the wires to the pins... that are mounted on a prototype board held with wood screws. It's like you were in a rush to finish. What happened there?

[@dekutree64]

Coarse threaded screws work really well in 3D prints. Machine screws need heat set inserts or the threads wear out quickly.

[@brilliantindianhacker3363]

Superb video very nice ❤️❤️

[@lorriecarrel9962]

Cool build

[@karljacobs794]

yeah its awesome when you to got all the tools and gadgets and knowledge to make it ;-}

[@TheElectronicDilettante]

Really great work!!! I’m curious, have you or anyone working with Axial Flux design tried also putting magnets on the edge(circumference )of the rotor and corresponding windings around the edge (circumference) of the housing? Or vice versa, magnets on outer edge of housing with windings on the edge of the rotor. I ask because because it looks like that would give you the best of an both worlds(Axial -Radial Flux). I looked around around the internet and didn’t find anything like what I’m suggesting, though I have seen a couple Rad-Axial motors. Congratulations on the success of such an undertaking and can’t wait til your next design hits you tube. Thanks for the video.

[@justacoffeemakerjr.9813]

on 5:32 shows a wye/star configuration scheme of this dual separated stator junction, my 1st question is how it's scheme to make it delta?, 2nd any significant different in speed and torque if it's wired in delta configuration?

[@zaildarkuldeep8451]

Good great job very nice. Thanks

[@alejandracerrudo260]

Alucinante😊

[@antoninperbosc1532]

Très bien mais pas de lien gihub pou faire un DL pour pouvoir faire un clone DIY et bricoler sur nos modèles réduits ?

[@Andrenalin77]

Beatifull, only think is wonder me that putting magnet into plastic case and rotate it with high speed doesn't bother you.

[@84edsl]

2 questions: How well does I work as a generator? What if you had an even number of coils and odd number of magnets or visa versa?

[@JF32304]

They don't make good generators. A truly efficient generator cannot be a motor and vise-versa.

[@agomezro]

Thank you so much for exposing the full process of construction. Could you also share the files to print the 3D parts?. Many thanks in advance.

[@garagewizzard]

Nicely done!

[@АлександрНехаев-к4х]

Out power 80 W, in power about 100 W. Efficiensy 80/100 = 80% ? Very good result if take account the coils w/o iron core.

[@АлександрНехаев-к4х]

@@platinumsky845 Maybe. Maybe. I cannot appreciate

[@ntal5859]

Actually for a electrical motor that is quiet poor most motors get above 92% mandated by NEMA some years ago.

[@hemantdaulta1]

Does anyone know how to calculate optimal BLDC motor efficiency? Like how many coils and how many poles, coils and how many windings. If prop and battery and TWR are fixed, then how would we get the optimal motor design? Also would the type of bearing also factor in?

[@harshavardhan2168]

amazing ......introduce water cooling as well and it is ideal for electric vehicles......!

[@neutrino4377]

What is the motor diameter? And does this design good for heating issue?

[@iamdragonkrys]

thanks a lot, very interesting.

[@SiriusFuenmayor]

how much is the efficiency reduced by not using iron cores inside the coils?

[@НИКОЛАЙРАМАЗАНОВ-ч5к]

Кпд увеличивается 100%

[@xmodalloy]

This is really not a great design. You've got nothing to try to direct and concentrate the magnetic flux through the stators. Ideally, you'd have one stator and two rotors with each rotor having an iron backing behind the magnets on the outermost sides (unless it's a Halbach array in which case you do NOT want a steel/iron backing on the rotors. You want the rotor magnetic fields to be attracting the rotors together around the stator. This does offer a mechanical design challenge, but you'll have MUCH better field interaction with the coils.

[@onemanmob6756]

I'm not an expert, but I also thought that without another rotor, half of the magnetic field created by the coils goes to waste. Ideally you'd have the cooil stator sandwiched in between two rotors with magnets

[@xmodalloy]

@@onemanmob6756 This is mostly correct. Not entirely, but enough to make something that fuctions a lot better than what's shown in the video.

[@commieTerminator]

at 7:58 the mechanical power output should be 0.15*7000*2*π/60=109.95 Watts. What is that 80W permanent power supposed to be?

[@Jackson-Sean]

Bonjour à quand une vidéo en français ?

[@bucknut87brutus81]

I see you used a 6:8 coil to magnet ratio, just for ease of build? Can you predict performance of motor with this ratio even before the build?

[@jwdean9163]

Genuine question from a layman - why is the motor noisy? With only one moving part, is it caused by the bearing or air resistance?

[@curtokay8046]

do you share the 3D print files

[@TheBatteraser]

Where can i find The 3D print stl file please

[@drumkommandr9779]

get this into the hands of the public as fast as possible. release the plans and get more fame than Linus Torvald.

[@pascalfust1035]

80W out of 330g of electrical motor? And this should really go into a drone? Standard brushless motors these days come with more power at a third of the weight. So, where is the gain?

[@natashamcgill1041]

Can this be used as an alternator with any modification such as a metal yoke behind the coils?

[@lernenmitrobin]

great work!

[@dipeshnangle4414]

Csn you please tell me, what will be the thickness of your wire which you used in this project

[@harribeydom]

0.6 mm

[@dipeshnangle4414]

@@harribeydom and how many turns have u done

[@dipeshnangle4414]

@@harribeydom Thank you how can i do all this calcualtions do you prefer any book or any other resource

[@harribeydom]

@@dipeshnangle4414 22 turns. We have multiphisics software like Jmag or Maxwell.

[@freddyfingerz9854]

Hey can you help me make and design a different but close style motor?

[@tomascancelliere4348]

Correct me if im confused but those magnets appear to be oriented axially to the shaft, not radially. The field would be perpendicular to the shaft if it was a radial flux motor. No? Or are those diametral magnets?

[@davidcharter5952]

okay the Copper Why Not Plats instead of wire

[@cleaningbeyondcarpet1167]

Is there any way to get the diagram to make one how much would the donation be

[@Urkylei]

a metal nucleo for coils not turns more efficient ?

[@bricodom31]

Yes the torque is 20% better but the weight 20% higher. it's a choise!

[@Eugene_Yav]

cool work

[@DAZprojects]

If i make It half the size, in your opinioni It Will be Powerfull enought to power a small RC plane?

[@EnergySeeker]

do you think i can a 3d printed generator coils without core ?

[@IneedAmmo09]

Any way we could get the models and materials?

[@erenkara5749]

Good work 👍

[@caagudelor]

Pero, si soy solo aficionado, y lo quiero implementar, como lo hago.

[@pavanra7453]

Hi, can I get these for experiments.

[@fretizpaulrenaison5771]

can i gent the link to the paper

[@peterwiley4383]

Could this be used for a wind turbine generator?

[@harribeydom]

of course like my vidéo on wind turbine generator but this one will be not very powerfull

[@vanshkumargoel6457]

hello , can you pelase share the CAD model for this motor please @Dominique H

[@stephenkolostyak4087]

okay, you're 3d printing parts to build an axial flux motor - what's the thesis arguing?

[@zachcarrizales5038]

I think it is more of an investigation to get a baseline for how an axial flux motor without any kind of iron (electric steel) core performs relative to how it might perform with an iron core

[@matinsakr6548]

Formidable.merci

[@frommarkham424]

If only EVs would sound like this

[@fritzgrief1140]

Could you put the wiring schematic in the comment section? I believe I understand the general idea. With the wiring schematic, I will know for sure. Thanks Really good video.

[@eugy2008]

Can this motor be used as a generator and if so, what advantages are there with two stators instead of one?

[@ChristopherKendrick]

What 3D printer are you using?

[@dominiqueharribey8723]

PA2200HD polyamide on EOS printer fine by Initial prodways

[@fernandoae]

stl´s? :)

[@prerupa]

essa é a parte mais difícil, medir o torque que um motor consegue produzir.

[@cyber_hacker]

how do you prevent them from getting hot?

[@vasyalapuh2878]

Print with ceramic ?

[@Guilin1234]

qual dimensão do fio?

[@harribeydom]

0.6mm diameter

[@warbot2544]

Why people count the rounds ( wanding) ?

[@quantumthings5894]

different round number change the coil caracteristic

[@warbot2544]

@@quantumthings5894 ty seems like I have to google it , to know in detail

[@saurabhphulpagar7950]

Great work sir and i have a question that which type of motor is good in terms of efficiency and power output for a given volume, radial flux motor or axial flux motor ( bldc)

[@OliverLloyd142327]

Generally axial will be higher efficiency because you can stack rotors and stators in a tighter space.

[@bricodom31]

the best is axial flux

[@dhruvlakra7827]

axial flux

[@samueladitya1729]

liquid cool it if you need much more power for small size.

[@mohammadamiri202]

what app do you use?

[@baluprasad1447]

How the motor speed is controlled without position sensor?

[@jakegarrett8109]

Most smaller brushless motors just use the back EMF to know position, if you want more info I would suggest looking at RC airplane and quadcopter motors and there are a few videos on how those work ("Great Scott" would probably be a good source for learning stuff like that).

[@baluprasad1447]

@@jakegarrett8109 thank you

[@leonelescobedo7887]

Awesome, how about the control? How do you achieve to commute the coils? Great job.

[@gagan_jit7897]

This motor give back EMF ?

[@harribeydom]

of course you can see it in the vidéo. It's a perfect sinus

[@gagan_jit7897]

@@harribeydom i mean how much efficent it is....... While running it give back emf ?

[@harribeydom]

@@gagan_jit7897 the effiiency is not the best because no iron. It give back emf like a classical synchronous machine

[@gagan_jit7897]

@@harribeydom ok done sir

[@yunielcortiza988]

Buen trabajo

[@azertaieb442]

Parfait... mais comme il fonctionne sans hall sensor!!!

[@dominiqueharribey8723]

Les onduleurs de type modélisme se calent sur les fem en faisant un autotest

[@azertaieb442]

@@dominiqueharribey8723 j'ai rien compris... mais merci en tout cas

[@davidchanget2563]

Do you have the designs for this motor? would you be willing to share? I would recreate and post a review video with my input as a mechanical engineer

[@fewthings8917]

Size of wire (swg)

[@jamesc2810]

Has no one heard of heating the enamel with a soldering iron. 400 degrees Celsius is all you need. You can tin it at the same time.

[@EinzigfreierName]

Nice build, but for a drone, this motor would be way to big and heavy compared to its power output. There are motors in the same torque and RPM range with higher power output and weight less than 50g. Saving weight is key in a drone application.