Homemade Brushless Axial Flux Motor Version 4 (3D printed and machined) | Dual rotors + Sensors

Finally this version is complete! After scrapping lots of parts I finally have a working prototype!
Special thanks to Colby Johnson, he made simulations on FEMM to see the magnetic field behaviours on my setup. Link to his channel: / @colbyjohnson2344
- Sensors: 41F bipolar
- Magnets: 10x10x5mm & 10x5x3mm N48 grade
- Except all the screws, the rest of the parts are custom made
Music from the youtube audio library
Original owner of the short clip of Fernando Alonso revving the V8 engine:
Todor - • Renault F1 V8 engine f...

[@karyjas1]

That is the kind of content ive been looking for. No need to rush, just continue what youre doing. Love an upgrading series

[@gatoninja4387]

IS EQUAL A MOTOR THE NICOLA TESLA HAHA ESC ,CONEXION STAR, INDUCCION ,IRON OR ALUMINIO....BASIC

[@JamesBiggar]

Persistence pays off. Well done!

[@foxxyytofficial]

Hey James, nice to see ya here ^^

[@OverbuiltByHenry]

Totally true! Thanks man!

[@Mark-ce7di]

wow

[@rexsolomon6325]

This guy will go very far in life. Great build! Congratulations!

[@B15HOP]

I am hell impressed with your work. I've been looking around for a good axial flux motor but have so far not been impressed until I came across your videos!

[@OverbuiltByHenry]

Thanks!! Next version will be sized to get a desired output power (hopefully) 🤞

[@unicornadrian1358]

Henry did a great job! Have you checked out Robert Murray Smith here on YT?

[@bingosunnoon9341]

There are no good ones. Eddy currents are the reason.

[@DeityImusic]

@@OverbuiltByHenry could me make this for me?

[@user-pk6dy3ey4u]

You are genius! There's not many people who can combine machining skills with electronics. be proud of yourself ;)

[@OverbuiltByHenry]

Thanks for your kind comment! I really appreciate it!

[@talopi]

I look forward to finding out what this motor's peak and continuous power is. Very cool!

[@r5bc]

Awesome work, please keep working on this project! I can't wait for the next versions and all the improvements you will add

[@colbyjohnson2344]

Awesome to see all the work that went into making this. Nice job. Keep it up!

[@e-powersport]

Amazing man! As someone who also sleeps where they work, I appreciate your passion. If you ever make it to the US, come by Vegas. Would love to work with you.

[@victoryfirst2878]

lOOKING FORWARD TO SEE THIS MOUNTED AND DOING IT JOB. NICE WORK FELLA TOO.

[@jc2044]

I must acknowledge your exceptional skills in accomplishing this task. You have my deepest respect as a professional.

[@luimackjohnson302]

Brilliant! Thank you Overbuilt By Henry in sharing this video in homemade brushless axial flux motor version 4, printed & machined dual rotors & sensors. Greetings from Madang, Papua New Guinea!

[@kizzerplowright]

Awesome to see all the work that went into this. nice to see a good old fassoined coil making machine.

[@foxxyytofficial]

Hey, i'm liking the updates and the progress on this motor ^^

[@kasra.rasaee]

Great work, love how you did everything by hand.

[@corneliuselbourne1044]

It was like watching a mini portal being built, great job.

[@caviarxxx]

what a pleasure to see a youngling working so smart like this

[@OverbuiltByHenry]

Thank you for the comment!

[@Ozzy3333333]

Great effort! To dramatically increase the power you need to REDUCE RELUCTANCE (flux resistance, the flux needs a complete and short path). How? 1. The coils need to be wrapped around steel. Being a single small bolt far away (many mm's) from the coil is a huge loss in efficiency. 2. the magnets need a steel back plate so the flux can travel easy between magnets. 3. minimize the flux air gaps. 4. balance the rotor If you fix all these, it will be minimum 4x more power, the high reluctance of your motor is killing its preformance.

[@OverbuiltByHenry]

Don’t get me wrong but I don’t get the first point, there’s actually a 4mm thick iron plate behind the magnets to prevent flux leakeage. I can’t minimize the air gap due to the stator being fully 3d printed and flexing due to the massive forces of the magnets on each side of the stator. Bringing the air gap down would stick the magnets to the stator, bending it slightly.

[@Ozzy3333333]

@@OverbuiltByHenry 1st point is low reluctance. Also the coil of wire should be tightly wrapped to the iron bolt to efficiently couple the winging flux to the bolt.

[@Ozzy3333333]

@@OverbuiltByHenry if there is a iron plate behind the magnets (that is good), why then ad a ALU plate behind that?

[@smartcenter4328]

Well done! Keep up the good work, matte!

[@donaldwright2426]

Great job young man! Keep it up.👍👏

[@em9594]

First, Great job! Love the video! Second, safety should be a top priority even in the home machine shop, no long sleeves, loose clothing, no neck ties or draw strings, no gloves, no rings, watches or other jewelry, when running mills, lathes, drill press or other shop equipment. Those tools won't care if they grind up a piece of steel or a soft squishy person.

[@user-he8qn6rn7h]

Well done, perfect job!

[@bablutu]

Respect to your work, I made an Axial too but it's out of wood since I'm limited in my tools but good job 👍

[@Truvies]

you did a pretty job on those coils!

[@markhagen7777]

Way to go the world needs more of you and bring your friends

[@ramzeneger]

Thank you for the design

[@8bit711]

Love it! Well done.

[@FilterYT]

Nice work, thanks for sharing!

[@chrishayes5755]

damn this guys living my dreams lol. one day we can compete and see who designs the more badass motors 😁

[@usamakr]

Great work. You make it look easy...

[@jsmythib]

Kinda looks like leading edge technology built out of stuff you had laying around. So, thats cool :) You should have a great future. Cheers!

[@robertling9872]

Thanks for sharing your intresting information and video.

[@andrebalsa203]

You are a very gifted and hard working young man and I am certain you have a bright future ahead of you. Keep going and my best wishes for your success.

[@OverbuiltByHenry]

Thank you for your comment! I appreciate it!

[@ejrupp9555]

Great work ... anticipating some wheel spinning go-cart burnouts in your future.

[@OverbuiltByHenry]

Thanks! That’s the plan!

[@jamest.5001]

This is awesome. I do think I'd try making the plastic parts that broke from carbon fiber coating a epoxy and iron filing core. Make the material to be milled into final shape. By using a hydraulic press and a 50mm pipe roughly 70mm long with a steel plate over one end, coat the inside with wax and make a steel or aluminum piston. That fits snugly into the pipe about about 35mm thick . Mix fine pwdered iron and possibly 20% by volume of black iron oxide. Mix the iron well then mix a thin epoxy measure enough iron to fill the tube 60 mm high . Use about half the iron mix with epoxy slowly. Until a thick paste is made, then add the rest of the iron. It should make a thick putty , play dough like thickness. Place it in the heavily waxed tube . And place the piston in the top. Start adding pressure. Keeping an eye on the pipe add pressure roughly 4-8 tons. Then allow the epoxy to setup. After about 4 hours remove pressure and allow it to sit in a warm place for about 12 -24 hours. Then remove it from the tube. Heating the tube until the wax melts may be required. Use heat snd solvents to remove any wax from the composite iron machine like normal iron. Only use light pressure and go slow to prevent breaking basically treat it like plastic. Making cores for the coils would be a great use, make the coil caps and a core in one piece the core can improve performance a fair amount, it should perform better than a laminate core. Definitely wirth trying. If you make the iron powder, use a old. Laminate transformer core make drill shavings and place the shavings inside a bucket with large steel nuts and bolts and make a rock tumbler from it. Maybe place 3 strips of 20mm angle iron attached evenly t the inside if the bucket and let it roll a few hours. The shavings should be powder by then. The iron oxide is to fill the gaps with iron. Use less epoxy . Making more inside a longer tube to allow all the cores tobe made from one batch. Buying iron filings is fairly easy. Alongwith iron oxide. Just a idea over the plastic, that will improve power output. Greater efficiency..

[@ShafaqIftikhar-pw9ld]

Thankyou for a beautiful video!!!!

[@THEOGGUNSHOW]

Nice video and workshop 👍

[@OverbuiltByHenry]

Thanks!

[@Putelquelee]

awesome. congratulations

[@rubendekkerallround474]

This is the best video i can find on you tube about this motor, i want to build one myselfe one day and use it in a electric hub bike. But desiging one will be to much of a learning curve for me, ever thought about uploading the design on the internet, or maybe selling the design, and also were to get the parts, maybe pcbway is an option for lots of people... Whats also would be a fun project is making a rc car 1/8 with these motors as a hub motor;) Thanks for making the vid !

[@snagle87]

Nice work! At ~ 14:00 I squinted and moved my head away from the screen in anticipation of magnets flying out from that 3D printed part.. Haha!

[@OrtexVideos]

This is really awesome

[@kiwiwombatman]

Great work !!

[@suryanova6231]

I love the vedios that has a ghetto feeling to it .great job man keep it up ❤

[@joelkist1]

U remind me of myself when I was younger I miss being in the garage and just building Cuse I enjoy it! Get vid love to see what you have in store for this motor!

[@OverbuiltByHenry]

Thank you!

[@swapnilmankame]

Was waiting for this upload since 3 months

[@OverbuiltByHenry]

I know it took a lot of time, I did it when I had time

[@DeonTolmay]

Brilliant mate .

[@OverbuiltByHenry]

Thanks!!

[@jacksplague3050]

Great video. Very impressive. Definitely subbing to see where this project takes you.

[@OverbuiltByHenry]

Thank you very much!!

[@BearMeat4Dinner]

Dude great lathe work!

[@OverbuiltByHenry]

Thanks!!!

[@nickoutram6939]

Well, I am really liking your workshop. I've built a few of these, smaller ones. The coils you have wound look great but I can't understand why you have two layers of coil with a plastic gap in the stator and the coil 'top' is another big chunk of plastic that is going to make the gap between coil and magnet even bigger... I would just have a single coil layer in the middle, try and minimise the air gap (no coil 'end caps' if possible). Also try experimenting with Hallbach array in the rotor magnets or back the magnets with at least 4-6mm of iron to allow the flux to 'bend back'. Finally if you can come up with a way to liquid cool the 3D printed coils/stator I think you will have completed my check list too! Anyway well done!

[@OverbuiltByHenry]

Thanks! To be honest I don’t know what I had in mind, I really wanted to test the dual rotor design and went for the first design I made. The version that I’m working on will be iron core, with halbach array and backiron, I did finite element simulations and seems promising!

[@bingosunnoon9341]

Good work. Maybe you will be the first to build an AFBLDC motor that has some value.

[@guidorafael]

incredible work!

[@OverbuiltByHenry]

Thanks!!

[@tarbaby6571]

Good job Thankyou for sharing

[@gordon6029]

Great build

[@karmaEbikes.]

nice work!

[@ali2naveed]

I have seen many creators but they always lack the build quality. they just put together parts and hope it will hold on. Your approach is totally professional and Build is commercial quality maybe better than Chinese commercial product quality. to be clear am not talking about materials. But to put things together. I will suggest to start an online company. Well looking forward your upcoming videos, already subscribed.

[@OverbuiltByHenry]

Thank you for your kind comment! If someday I achieve some decent results most probably I will put together some sort of "motor kit" to sell.

[@leadbadger9543]

looking good!

[@jhon614]

You have my sub. Great content!

[@OverbuiltByHenry]

Thank you!!

[@icraftcrafts8685]

you're doing great work

[@OverbuiltByHenry]

Thanks!!

[@suntzu6122]

KEEP UP THE GOOD WORK MAN!!!!! HOLY SHIT NICEE!!! WELL DONE!!!

[@sidratal-muntaha4513]

This is the same thing as Emrax Motor good luck ❤❤❤

[@tatradak9781]

What dedication is very impressive...hugely inventive.. are you considering dual rotor, the results seem to be extremely positive.

[@b77motorradsattlerei]

Que grande...!!!! Proyecto super currado; y el " cago en deu" me ha encantado , cuando pienso en cuantas veces me he visto en situaciones así....😂😂😂😂.... Te acabas de ganar un subscriptor. Sigue así.

[@OverbuiltByHenry]

Muchísimas gracias!!

[@simodinar]

Brilliant 👍

[@vondarycrentsil9180]

It had so much power that it actually tried to move off the platform, nice

[@SeanODonovan42]

Brooo where did you learn about axial flux motors? I'm an engineering student (1st year) and I have built some stuff, but none of it required your level of machining skills or the engineering knowledge you display having in your video. That's so neat, quite frankly I'm jealous (but also inspired haha). Great work, literally no employer can look at this video and turn you down.

[@kristal1624]

Great job, thanks 👍

[@teropiispala2576]

Nice project you have. You may want to try lost pla aluminium casting when you find configuration which works the best. Those 3d printed parts can't take the heat and are not dimensionally stable under stress. You seem to have equipment to finish aluminium castings to good tolerances and surface quality.

[@OverbuiltByHenry]

Thanks!! Next version will only have the casing and the coil cores 3d printed, everything else will be metal. I didn’t show it on the video but due to the massive force from the magnets on each side everything was flexing, that’s why I had to extend 1,5mm more the middle shaft on each end to prevent scraping the coils.

[@teropiispala2576]

@@OverbuiltByHenry I have made quite many of those castings. Easiest method is to print part with thin wall (0.5-1mm) and only few percent infill and then bury it in casting sand and pour hot aluminium on it. With good amount of ventilation channels, all vapour can escape and surface quality can be pretty good. I have specialized casting filament, but for this method, it's not needed. Transparent or light colored pla works fine. Don't use black filament. They often use carbon or such as a color, and it doesn't burn away. For higher precision and better surface quality, I use plaster and sand mixture and I burn the filament away. This process requires special high temperature owen and some level of work to get everything right. The mold can swell or crack with wrong kind of sand, mixture or burning temperature curve. When everything goes right, the part is shiny and smooth and measures are accurate. Part shrink when it cools, so the mould must be bigger than final part. I use 1.2%, and it's usually OK.

[@mzimmerman1988]

very cool!

[@superestoque8346]

What a talent, congrats. Just take Care using long tshirt operating lathe. Subscribed

[@goldbornmusic2025]

Awesome👍👍👍

[@mikek1187]

Bravo to you and your work on this motor! Please keep it up, I'd love to see what it's capable of, once you are finished with the project. Maybe, if you're willing, even offer your plans for a few euros for those interested in duplicating your efforts?

[@OverbuiltByHenry]

Thanks! It was only a test if the dual rotor "setup" was feasible. When I was building it, I had problems with the major part of the coils, they were separating. I had to re-machine and re-print some parts to accommodate the extra thickness and thus have a working prototype. If everything went the way it supposed to, probably I would had it uploaded somewhere.

[@blakes8901]

that intro clip was hilarious

[@ramonfernandez9508]

Excellent job!! I have a question, why in axial flux motors the windings don't use laminated iron core? I understand that laminated iron core maximize the magnetic field best than air core, is correct? Can someone please answer?

[@OverbuiltByHenry]

Yes, you are right. The air core exists because there are no eddy current losses on the stator made of iron core

[@JustinJJHCS1]

yeah, this is why the coils are encased.. And compressed but this good enough for a Prototype..

[@JerseyJanette]

Good job.

[@pcpatel01]

may we ask how many turns per coil and size of the 3d printed part on which the wire is wound?

[@damirdze]

How come I did not subscribe to your channel before? Good work. Thanks.

[@OverbuiltByHenry]

Thanks for your comment!

[@justinromang9113]

what a BIEST -- take Care & KEEP IT UP

[@CapitanNEURO]

ciao non guardo tutto il video ma ti posso dire che sei proprio bravo

[@OverbuiltByHenry]

Thanks!

[@letsfixit1594]

Nice job, any chance of making the 3D files available?

[@allendaigle6351]

What a genius

[@garbageman3992]

why does it need active cooling? especially under no load and just testing situation it should not need active cooling if designed right? Im assuming the cooling is for future projects with it where high power output must be achieved. really cool video!

[@Eloybb1]

El realmente gratificante como todavia hay jovenes que tienen la necesidad y la capacidad para ser curiosos, y apliquen los conocimientos en la practica y intenten sus diseños y sus pruebas. Me da la sensacion que habla español por el acento de su español en el ingles. SIn lugar a dudas, es el flujo axial rescatado de los ordenadores de los años 60s quien posee una alta densidad de potencia y eficiencia, con tan solo 14 kg ya esto viendo motores de 75kw en continuo con 120Nm. No me queda claro si hay puesto imanes en el rotor, pero imaginate que si los lleva, aumentaria su potencia... con los de neodimio

[@jalildragneel2674]

What material are the steel disks or how do you keep them from rusting

[@nwsteg2610]

What is the tool on the lathe at 10:00 called? I haven't seen something like that mounted perpendicularly before. (Although, I don't know much about machining.)

[@philthy5690]

Idk if I missed it, but what are you planning to mount this on? Can't wait to see it!

[@OverbuiltByHenry]

I started prototyping these motors because it’s very hard to find something decent here in Europe, and if I find it it’s expensive. I build electric vehicles and other stuff that has a motor, that’s why I’m trying to make my own motors.

[@mohammaddh8655]

i love it is there a book or any other source for electrical motor that can teach all the basics of how they works im love to learn

[@MdMubin-bp7wp]

Hey Bro, how did you fix the bobbin of the stator with the motor body?

[@clonkex]

I will say you in the next one too ;)

[@apaskiewicz]

Wow that's really impressive. Where did you get your 3d printed designs?

[@OverbuiltByHenry]

I designed all the parts myself

[@bluez6812]

this is really cool, I am in highschool and I am trying to build an electric go-kart and an Eike with my own axial flux motor, I was wonder if you could help me, I am really confused on the coil to pole ratio, and the controller

[@OverbuiltByHenry]

Thanks! If it’s your first electric build my strong recomendation is to go with available components, building your own motor is not that simple, I’m still doing prototypes of my motor. You can send me a message on instagram (@overbuilt_by_henry) and I will try to help you

[@leonardoaugusto5491]

would a epoxy and iron powder composite be a good iron core for the stator in therms of magnetic permeability? i would like to see someone trying that. High temp Epoxy resin + Thin Iron Powder

[@abyssalblue3089]

Most impressive! I literally smiled when you whipped out your calipers at your lathe👍 My only suggestion is to invest in a breadboard and start prototyping your own electronic circuits. Commercial stuff is typically all garbage, components sourced from lowest bid suppliers.

[@OverbuiltByHenry]

Thanks! I’ve been into arduino lately, I don’t record it but I also love tinkering with electronics

[@abyssalblue3089]

@@OverbuiltByHenry keep it up! All these skills are worth big money in the Job world.

[@kkuhn]

Will you release your design?

[@Traderhood]

What size of wire are you using? And is it rectangular?

[@nagarjun41]

Would love to replicate this. Do you have the design details to follow?

[@BHARGAV_GAJJAR]

Very cool how did you pick back iron thickness

[@OverbuiltByHenry]

There’s a rule of thumb, the thickness of the back iron is half of the magnet height/width (depending on the orientation)

[@marlonlacert8133]

Would it not be more efficient if only the centre rotor turned, between two magnets coils? Oh and print an air blower in centre, to keep motor cool?

[@odd13579]

very impressive! quick question, i notice that you doubled the coils on the stator, i presume this supports the desired power levels. could there be any benefit in splitting the stator so each set of coils straddles the rotor? i mean, is the double stator with "keeper" back plate on the other side of the rotor equivalent to the magnetic circuit with a single set of stator coils on each side of the rotor (of course, each backed with a high permeable back plate)? just curious. thanks again for the great video!

[@OverbuiltByHenry]

As far as I understand it could be driven with two separate controllers if I didn't connect together the coil from each side. To be honest, with that design I had to split the coils and connect each one in parallel/series, at that time I went with parallel for lower Kv and more torque, but I insist, this prototype was only to check if a dual rotor setup was possible, and sure it worked. Hopefully soon I will have time to test it on the dyno.

[@odd13579]

@@OverbuiltByHenry thanks for the quick and clear reply!

[@radovansemansky4618]

excelent 👋👋👋