Brushless DC Motor

thingiverse

This motor is for a university project (ENGR 320, University of British Columbia Okanagan Campus), where I am a third year mechanical engineering student. We are required to design and build our own electric motor of any type. I decided to build a brushless DC motor, in an in-runner configuration (rotor spins inside the stator). This project has consumed a lot of my time and has been a lot of printing and reprinting for tolerances. Here's a list of material I used and what for: Stator Shell (casing) - Red PLA, 0.2mm layer height, 30% infill End Caps - same as before, more infill as the bearings locate in this and support the shaft Stator(inner) - Protopasta Magnetic PLA where I wound the 6 coils (this is split in half because it would be almost impossible to wind otherwise) Rotor - Black ABS, 50% infill to save on weight but create a strong part Shaft - 5mm stainless steel rod, (may be a good idea to use AL as its not magnetic) Bearings - 5x11x4 RC bearings Windings - Delta configuration, using 0.067mm copper enameled motor wire Hardware - 8xM3 cap head screws Magnets - 4x 30x10x4mm neodymium magnets Speed Control - XP Digital Brushless ESC with Axial AR3 controller/module This project is not yet complete, and my knowledge of building motors is small, but I'm doing the best I can and hoping it will work out! Hope you guys can enjoy and maybe make some improvements, let me know what you think! EDIT: I have completed building the motor. The split stator windings needed to be sanded a bit to fit snugly into the stator housing and I drilled 3 holes in the back cap in order to feed the wires through. I wired the motor in a Delta configuration. Hopefully it works! Will update once tested. EDIT #2: This motor was a fantastic project! the wire could have been much thinner in order to get more windings, but other than that, it worked decently well.