3d-printed Halbach Motor - Building Instructions

[@4.0.4]

Just building this is a lot of work, now researching, designing, testing, and making such a quality video with nice graphics and footage teaching about it is something out of this world. The craftsmanship is ridiculous, you even took care to measure each magnet, it's a work of art. You sir are an amazing person. I'm speechless. *However I would still be curious about how badly it shatters when really put to use*

[@styrbjornoborna4660]

Yeah, I can't even imagine how did he draw those coils. Winding the wire is not a valid operation in a CAD system.

[@joonasfi]

@@styrbjornoborna4660 I was wondering that as well!

[@eliasjohanliavaag]

Winding a wire can be done by using a sweep in most CAD-programs. But a lot of work, nevertheless! :O

[@reforgedcriterion1471]

When he measured the magnets I suddenly realized I've been living in a cave all my life..

[@happyfox711]

He's German(Swiss actually), there's no other way to do anything over there ;)

[@mojojomo6750]

That magnet-rating methodology is a real eye-opener. I never thought there would be that much variation between like-magnets. It would also explain the differences in performance seen in builds when the characteristics of individual magnets is not taken into account.

[@erinboatguy]

the drill press and soldering iron pop up pics are hilarious....they made my day !

[@MrBENx9]

such a sad day

[@mauriciolima1088]

your attention to detail is IMPRESSIVE. I would have guessed all magnets were the same, that was a great catch.

[@Harrzack]

The MOST amazing, thorough and competently done YT video I've ever seen! Also a great display of what is possible with 3D printing. Kudos Christoph!

[@TC-um2ti]

Finally, someone who wants to share and cares enough to teach others as well. This is the one of the best teaching videos I’ve seen on KZbin! You did very well using graphics and as well as explaining and demonstrating with your hands. I feel like building my own motor is actually possible.Thank you very much. I hope you are inspired to share more.

[@Jer_Schmidt]

That is a really great design, very well thought out

[@e.arenoe7509]

@Larry Jackson nahh we here for the motor. thanks

[@pernaboys]

I'm an engineer, watching these stuff makes me question my life and my non existing achievements

[@pernaboys]

@Semper Fortis Well, it really depends on your environment. I never had a friend who was interested in doing these stuff. it's not easy to be a self taught in everything. I learned to code from the internet and before that I learned how to speak English from movies thanks to the current technology. So, not everyone has as good as you. living in a third world country under lots of sanctions is not easy. I know, you don't care and I don't want to bore you. I just wanted to give you a context for your prejudice. peace

[@RocoeGames]

@@pernaboys idk man I have some friends that just live and breathe work and improvement. I wouldn't say its all enviroment. I am in the same situation where I don't achieve much but im also not constantly trying to, unlike my roommate. Guy works like 60 hours a week minimum doing personal projects and shit

[@pernaboys]

@@RocoeGames Well they like their life I assume and they are not depressed.

[@RocoeGames]

:^(. Find personal worth thru a hobby Breh. Doesn’t have to be technical

[@lyteyearz5810]

Brother maybe it's time to change your environment! I say go for it! I never became an engineer but only because I didn't apply myself and now i have a few regrets but that's life and I'm working on fixing it! But seriously if you're an engineer, surround yourself with people that will push your thinking to its limits and get rid of people that say "that won't work" or "you can't do that"! I have a lot of moments where I only want to create by myself but there are definitely times where I wish someone would visit just so I can say "hey, look at what I built!". Good luck brother... push harder... learn more....achieve more. One day you'll wake up and be old and then it will be too late. DO IT NOW! 💪🏽💪🏽💪🏽💪🏽😊

[@carlcrott8582]

This is brilliant work. I have not enjoyed working with a hardware engineer of your skill but I imagine I would be floored. The fact you knew to measure both variance in weight AND the magnetic force generated by the individual magnets was perfection. The measurement jigs you designed were wonderful. And watching your thought-process of managing BOTH magnetic variant forces AND the weights were pure novelty. Again I HOPE one day to work with an engineer who has this level of polish and insight. A+++++++++ That being said I cannot for the LIFE of me figure out how you europeans make ANYTHING work when you've swapped decimals with commas and commas (1000-increment separators) for single-quotes. lol.

[@Blox117]

yeah i didnt think about the magnet variations

[@MoempfLP]

I recognised the accent immediately. Cool to see a fellow countryman realizing such amazing ideas.

[@pietermeyer5921]

Swiss?

[@MoempfLP]

@@pietermeyer5921 Yes

[@zach3360]

11:16 really helps the understanding of magnetic poles and how they are positioned

[@henrylo6773]

The amount of trust you have for that 3d printed piece of plastic holding what potentially can decapitate you is astonishing.

[@funafter5081]

Absolutely amazing work...just like a Swiss watch! I will be watching for future updates and videos for sure...can't wait! Keep up the great work. Cheers, John

[@OpTicBossaru]

There is a single moving piece. It is nothing like a swiss watch. Swiss implies complicated, this is more japanese, like a Casio. So well engineered it doesn't need a ton of moving parts to make it work. This is something germans and swiss just can't get out of their heads, they make some of the best stuff, but it's all overly complicated. Case in point: look up the G11. It's a rifle the germans prototyped. It used caseless ammunition, and had a trigger pack so complicated it was sealed to keep out debris, and if there was an issue with it you threw it away and got another one.

[@marcferretti]

Shut the fuck up.

[@evilrobdog]

Finally someone on KZbin who makes this sort of thing and has a care for detail with a easy to understand description explaining how everything works. I am subscribing in hope there is more great videos like this.

[@ATLfletch]

Great video. I have no intention of actually building one, but I've learned a lot about these type of motors from watching your very detailed instructions on this project. Thank you!

[@dragoro3033]

Of the many things I am going to be doing in my life (I am studying to be an engineer and have finished my second year of college already) I want this to be one of the early things I do. Thank you, I look forward to this project. Please leave the video up as far as the internet will allow!!!!

[@punisherek]

I have watched this video several times now and every single time I am equally impressed - absolutely amazing work.

[@TheBowersj]

You sir are amazing. Never would I have thought a 3d printed motor would work as good as this one has. I imagine a day when a poor person in a developing country prints his own generator for pennies and builds a wind turbine that powers his families drinking water pump or household power. Thank you very much for making the future world a better place!

[@jumbleblue]

this was very very impressive!

[@noe8740]

one of the best videos using 3D printing technologies and electrical motors, keep up the good work and keep up sharing your knowledge this is what life, learning and sharing is all about. congratulations.

[@Colarocker]

wow, the level of detail and thought in this project is really amazing! for every small problem there is a solution, like the small holes to push out the magnets. i hope i will reach this level of ambition someday ^.^

[@DiegoTomohisa]

I am amazed at the amount of power you manage to get out of it! 600 W for something fully 3D printed... Seriously impressive.

[@VAXHeadroom]

Very nice ideas for measuring the magnets! Great build.

[@firstjayjay]

YOU KNOW WHAT!!! these days ppl say, 20-50years ago we could fix cars our selves, now a days you can do sh*t- While this is true, 20-50ye ago you couldn't build a freaking motor at home. 3D printing and CAM programs have really made literally anyone doing anything. Some are even building rockets leaving the atmosphere. Try doing that in the 70's. Great vid.

[@MarionMakarewicz]

I have so much enjoyed watching your videos. I have learned more about motors than I ever had before. Nothing like building something to understand it. You do a great job in editing and narrating your videos. Your humor is super. You rate up there for me like ThisOldTony. Keep the, coming. Looking forward to a plane flying with your big motor.

[@arifanwari3168]

A proper teacher on KZbin, thank you sir, too many scumbag click baiters on KZbin. You Sir have restored my faith.

[@tanmay8017]

Watched Great Scotts video this morning, and KZbin recommended me this.

[@JohnSmith-rn3vl]

If teachers could all be as good as you the world would be a much better place in 20 years time. Amazing.

[@sakirabbit900]

It's beautiful. Thank you so much for your hard work and ingenuity!

[@Zarrar2802]

I'd rather buy a motor, I'm just here for the soothing voice. Had the best nap ever! thanks

[@jacky1255641]

You're a genius! Incredible

[@benjastram7094]

Great work Christoph! I purchased the files yesterday and we´re just printing the parts in PA12 on our SLS-machine. I´ll keep you updated if you want.

[@bruperina]

Came here from Great Scott’s reference.

[@joonasfi]

Same!

[@AnandKumar-vz9kk]

Same

[@nilswegner2881]

Me too

[@abdelssami]

same

[@CRISAP94]

Same

[@samrockseagle]

I can't say i built this motor, but certainly enjoyed watching your video. Amazing work.

[@edgeeffect]

Drill press, soldering iron! :) :D :) I love your procedure for testing the magnets.

[@Rex-p4i]

Amazing ... Thank you. I built your slew bearing with 68 roller.... works great. What changes wld be appropriate with metal 8mm diameter by 8mm long rollers. The edges of the rollers are squared off .. not chamfered.I love your detailed work and the way you break down complex things we use everyday. Well done 👍👍

[@Eric.Poirier.]

FINALLY a great and usefull recommendation

[@johnnyb8629]

the cool thing about this motor design is it could be done in titanium with porting for a cooling system. the rotor can be dynamically balanced and the bearings optimized for the torque direction. With titanium being the material the thickness could be reduced making the overall size a bit more manageable. Applications for such a motor could be drones augmented with PV panels for aerial surveillance.

[@nrdesign1991]

3:32 this can irreparably damage the bearing. Push on the outer ring to relieve the balls of stress.

[@falcone7908]

Or just put a small rubber cube in between.

[@bbushong67]

I'm guessing the minor side pressures of pushing a steel bearing into a plastic hole probably isn't going to hurt it...

[@nrdesign1991]

@@bbushong67 It is generally bad practice.

[@TheWeirdSide1]

Somewhere all over the place is a hot glue gun and a man from India making sad versions of this and raking in 10 millions views...I'm lucky I found this video and even more lucky you made it! Thanks!

[@LoganT547]

14:43 You'd definitely want to be careful around one of these motors, especially seeing what it did to your background!

[@Megaflare47]

Small brushless and even brushed motors spinning props can take off fingers...imagine what one of these could do to your arm!

[@LoganT547]

@@Megaflare47 Yeah, especially that the prop didn't even slow down when it chopped the background concerns me.

[@rooneyosman9]

I am speechless. you are more than amazing. I have learnt from this video more than what I have learnt for the whole semester at Uni

[@electronicshelpcare]

Thanks sir. Really it’s helpful video for us. We can learn

[@bramza8853]

you could start a fricking airplane with that thing! Good job that thing looks powerful as idk what to compare it to. I have never seen this level of quality on a homemade project video.

[@brianbrewster6532]

All along I was thinking, nah this is gonna be well-intentioned but useless dud like so many other 3D printed parts we see. But holy mother of God - I was blown away by your fantastic invention. I can see these used in hovercraft, air boats, boat propellers, etc. Qs: 1) How much were all the materials? 2) Max RPM of the motor? 3) How much DC current were you pumping into the winding? 4) How much overall did this motor weigh in kgs?

[@EddSjo]

Brian Brewster Uhm, i mean, those don't run on dc.

[@nathanrogers8713]

IsbjornXII News flash... This is a Brushless DC motor...

[@nathanrogers8713]

As to the rest of the questions, Most of that info is in the Instructable that is linked. Current depended on the voltage. It was tested from 8V to 30V. At 8V it drew 80A. 20A at 30V. Rated at 600W and spec'd for 8,000 RPM. Total weight was 900g or 0.9kg.

[@MCSGproject]

Will never be used in anything, inductance of magnetic print material isn't enough

[@ascari100]

@@MCSGproject this design doesnt need an iron core.

[@ПавеЛСемашкО-ы5ц]

You are very bright and very consequent and logical engineer! Great job. Good luck. Of course like!

[@Gounesh]

this is amazing. hope u make some droning with these bad boys. subbed, liked, commeded.

[@Дмитрийсергеевич-о9п]

За такое памятник ещё при жизни надо ставить!!! Отличная работа!

[@ewap-by-daniel]

Genial, ich gratuliere zu dieser brillanten Arbeit. Beste Grüsse aus Thun.

[@nickvledder]

Hünibach!

[@ewap-by-daniel]

💪 👍

[@kencraig2178]

Spectacular. Really impressive build and instructions. I barely caught the drill press picture, but then I was really hooked.

[@bexpi7100]

"A decent drill press"

[@holodrio1719]

@@extremecupcakebaker its about tourque and how round it runs pffffff. *pushes up glasses*

[@kimaegaii]

Can you not do this without a decent drillpress?

[@holodrio1719]

@@kimaegaii surtainle

[@NightRunner417]

Verrrrry very nice, excellent work. I love the whine it puts out at certain RPMs. When you fired it up hard with the propeller facing the right way, I felt that old familiar rush... Power, baby. Beautiful. :-)

[@KerbalLauncher]

Oh wow, it's a real PMSM, the windings are distributed. Which means should really use an ESC capable of field-oriented control. Trapezoidal control might be why delta configuration experience high recirculating currents. ESC that claim "sinusoidal control" do it through voltage control, which performs poorly at high speeds due to phase lag in the current waveform.

[@philiperrendesign8362]

Watch my DIY 360° Bluetooth Speaker: kzbin.info/www/bejne/mZuZmoiwi8SSoMk

[@Chris_Goulet]

Mars colonist technician tells his assistant: "The blower motor in the oxygen generator is shot, go print me a replacement". Assistant comes back with a few parts, and says "I've placed the order for the bearings, they should arrive in two years".

[@danielch6662]

Canibalize the bearings from the old motor.

[@Chris_Goulet]

@@danielch6662 The bearings are the most common cause of motor failure, so the old ones are likely bad. The supply chain to Mars is going to be a nightmare. They will have to stock bearings for all critical motors, because bearings need tighter tolerances than printing allows.

[@Vikcreed]

the plant is cover in iron oxide and aluminum. the 3 top elements. cast them in a thermite forge and you get iron. throw in some alloy to get steel and ect, or you could use induction too.

[@doc-holiday]

This video was so beautifully presented and explained through 3d models and putting it all together was simply amazing just to watch. So much detail went into this brushless motor.

[@TANK_The_Hammer]

I'm curious as to what the power output would be if this where to be used as a wind turbine generator

[@lee503]

TANK The Hammer I'm thinking the same thing.

[@Kal-0000]

TANK The Hammer use kinematic equations???? I mean all data needed is shown in the vid..

[@TANK_The_Hammer]

Sry I never got into AP Physics

[@ChristophLaimer]

80% of 600W (at 6'500 rpm) --> 480W

[@TANK_The_Hammer]

Christoph Laimer thank you very much, so 2 units would generate nearly 1KW, that's pretty sweet

[@martingraser6938]

Absolute well done! Respekt.

[@winfriedrijssenbeek1]

Excellent work and craftsmanship! So good. in 2015 I was also studying Halbach array motors, and saw the potential. Now you can do it with 3D printing, great!!! What is the power to weight ratio of this one, as compared to regular brushless? Is it worthed also in relation to the power output/per weight of magnet? hope to hear, best Winfried PS we are currently developing mega drones of MTOW of 200 kg and 100 kg of payload, have 8 motors each 2 to max 15 kW, with 4kg each. So that's why I ask.

[@dissonantiacognitiva7438]

Can you explain the width of the poles with regards to the effect? Because in between the south and north orientations a magnet is placed in between but of different width, what is the overall effect? Or is this more of a design thing?

[@Umdloti]

Well done Chris, amazingly simplified by your excellent video. Now I want a 3D printer.

[@SezerYalcin]

Another German doing crazy things

[@ElRealista7]

No swiss even worse

[@lyteyearz5810]

This is soooooo cool! huge smile on my face. Thank you for uploading this. Very inspirational!

[@regpugh9021]

Hi, really good project. Just thinking could this be adapted as a wind turbine generator. Reg

[@johndoe-lr2fi]

Thats really a peice of work u build their just saw it pushing an untra light on flight test VERY COOL Man u could go into mass production well done

[@vladislav9454]

Круто получилось, только как отводить тепло с обмотки медной проволоки?!

[@simon2644]

Ну он предусмотрел это и сделал отверстия для охлаждения

[@dena5498]

Он сказал что метал не безопасен. Конечно он выполняет роль радиатора, но так как двигатель будет внутри обдуваться, также как и топиться, то при такой мощности можно обойтись пластиком.

[@clarkso65]

Sooo detailed, you will need all the patience in the world to make this! Good job man 2 thumbs up.

[@LowkeySmoothy]

Right after this video ends, I got a suggested video titled "is 3D printing a motor possible"...

[@Phenom5]

That's some absolute quality content I want to see more often

[@ITpanda]

How long can you run this at 50% or 75% (usable lift) speed/voltage before it malfunctions given active cooling from the prop?

[@AlexTBon4073]

Considering the cooling holes, not long.

[@Mr.ky89]

The engine is beautifully designed and strong, high speed is great.

[@pseudotasuki]

@14:47 It works!

[@user-qx7tm5df8j]

haha xD

[@absentbrainded]

LOL. Who saw that coming at 14:45? Excellent work though. Thank you for this video. Very cool.

[@TommieDuhWeirdo]

holy fuck that's terrifying

[@jasongooden917]

when it knocked over the wall i laughed so hard i had tears in my eyes.

[@evanthelegend7610]

Super powerful RC boat? Also a super large airplane. Great vid, this is getting me excited to build one too.

[@Mirandorl]

Could you use a kevlar print material to add a destruction proof outer layer in case of catastrophic failure? I have seen videos of guys using kevlar to make tow brackets capable of pulling a car. I would also like to try making this is the base for my LIDAR spinner I want to make, its been hard finding the right motors. Do you think it would be possible to modify this so its hollow shafted?

[@xaytana]

Kevlar, like fiberglass and carbon fiber, is a material you bond with resin, either chop mat or woven. There are a few printers out there that use fiber in the shape of filament that are extruded but the material is placed into plastic and the filament is cut; you're not actually printing it, it's just placed within the model for structural support. Personally, I'm skeptical at the benefits of added material, since it's not being processed in the same way as it traditionally would be, with resin. If you're building for failure protection, it'd be better just to lay up the kevlar/glass/carbon onto the outside of the motor, like a cast. But with the wall thicknesses and infill, this should be more than enough if there is an internal failure.

[@ChristophLaimer]

Wireline the mark 2 printer from markforged prints continuous fibers. it's 10 times stronger than normal 3d-printed materials

[@Michael-on5ft]

I'd love to see a motor build with the mark 2 *-* Pls make it happen!

[@Michael-on5ft]

Pls make one out of Nylon or an other strong material an test it :)

[@benb8075]

Would still be pretty fragile to shear in the x/y plane, though? I imagine it's much more resistant to pretty much any other force.

[@SigOther]

no kidding, this is the best show and tell ever! thank you for something so perfect in every way!

[@Arek_R.]

Is it really worth to build that motor? Isn't motor from hobbyking cheaper than all these parts and job?

[@ChristophLaimer]

Buying is always cheaper than making something yourself. This motor is clearly an experiment using 3d-printing technology, and not using traditional iron-sheets. it's also educational ...

[@Arek_R.]

Yeah really enjoyed the vid, didn't knew that we don't have to use iron core...

[@Taunus-Tim]

Arek R. But did i understand right, that the plastic used for the rotor was conducting? It has to be or am i wrong? Just copper wire without a iron core would work, but with a very low power of the motor!?

[@ChristophLaimer]

The plastic used for this motor is not electrically conducting. It's basically copper wires, permanent magnets, and no iron core. Resp. the stator is printed with PLA, blended with 30% iron powder. However the effect of the powder is marginal compared with real iron laminations.

[@Taunus-Tim]

Christoph Laimer thank you. So i misunderstood this. Technical English is still kinda hard for me to understand. If you had a laser cutter or a flowjet cutter you could easily build a laminated iron core from sheet metal.

[@pancake_crab4457]

Hmm. We have reached the day where I don't just have to buy a motor, but I can make one myself now. Amazing work!

[@nedos7847]

I would turn my bike into an e-bike, if I had a 3d-printer.

[@netto880]

can you build a motor DIY?

[@aserta]

I don't think it could take that kind of load. It's a plastic case at the end of the day. You should look towards finding the most common fan that can be run on a battery, then, instead of a battery, use capacitors (round shape will help you hide them in a neat package). Not really that amazing of a e-bike, but certainly a lot cheaper than paying 2000$ and up.

[@Chaos------]

Casting small things is not difficult to do, and I think most of the parts would be easy to press into casting sand and leave their impression more or less perfectly.

[@inferno7181]

why not just print the entire bike?

[@a0flj0]

@@aserta Electric rollers have way less powerful motors. You reach 30 km/h standing on a narrow board connecting two small wheels on this. That's already quite dangerous - the smallest pothole can send you rolling. The force being transmitted doesn't need to be that large, and the shocks and the really high dynamic stresses would be supported by the frame, not the motor. If I can find the time and the instructions to produce something maybe half as powerful but a hundred times slower, I'll definitely try to print something like this. Most rollers available for sale today have really small wheels - not good for bumpy roads. One with larger wheels, with the driving motor inside the hub of the front wheel, would be ideal.

[@pikejuan]

This was an extremely informative video. I would never have thought to balance the magnets and certainly not the way you did. brilliant end to end instructional. i stumbled across this video in my feed and i am glad i did. Keen to see what else you have.

[@SCM]

which 3d printer was used for that?

[@sananekrds561]

SubConsciousMindd ultimaker 2

[@kalinwang1]

Dude, you changed my life.

[@kingskiller1253]

😂😂lol 14:43 but excellent job how much it costs you?

[@ikki7817]

Idk probably cost him like 5 bucks, it was only a foamboard that fell

[@guchaves1976]

Such an excellent project! Thank you so much. I think this is really the beauty of 3D printing!

[@mauel2794]

Quien más vino después de ver el video de un poco de todo

[@tu8348]

Tienen los planos :v

[@reforgedcriterion1471]

Wooo I'm definitely going to have to watch this 4 or 5 more times and even then I don't think I'll have it figured out.

[@arjey9669]

"ESTO ES UN POCO DE TODO"

[@ss-sq1hn]

There is one advantage for this and it is that 3d printed parts can be really light so this technology can compete in weight to power ratios.

[@After_Tech_Industries]

with a motor that strong you could make a 3d printed lathe

[@jamesscott8962]

Thank you! That is one of the most comprehensive and polished tutorial I think I've ever seen. Not only inspired to make a cool motor, but hope to one day make a tutorial as thoughtful. Absolutely amazing. Can include a shopping list of where to get the parts?

[@owaisfarooqui6485]

Buy a 3d printer Print a 3d printer Return the 3d printer. LOL.

[@MrDoboz]

owais farooqui yeah, you have to print 4 stepper motors, one for each axis and one for the feeder, now print a cooling fan for your extruder, print your bearings, print your shafts, print the pulleys and the cogged belts... That's already more resources than the price of the 3D printer, and I still didn't talk about the heating elements for the bed and the extruder. Good luck with that dude.

[@peterv2485]

That’s not how it works fam

[@maximilianraab18]

Those 3D prints are so clean

[@azobchajin1491]

Thank you for listing the details in your description links!

[@t.hartig4570]

Schweizer Präzision! Macht wirklich Spaß zuzuschauen!

[@philbo-ld2eh]

Awesome work... richtig beeindruckend und Inspirierend Herr Laimer!

[@idribbledonyou]

Utterly outstanding work and presentation, that is a seriously understated level of experience.

[@vinishshetty8055]

one of the best how to videos I have seen you need to do more videos sir may be projects like wax working lathes, wind turbines etc...….Possibilities are endless!

[@christianbehling2]

I've never seen such beautifull thing on the internet

[@martinrodriguezmelgarejo8869]

you are the king of the 3d printers

[@bernalaso]

This is the coolest video I've seen in ages!!