[Lordcx]

Hi every one.
I've made a small size 3D printed outrunner brushless DC motor but it is not working. It has 9 stator slots with ABCABCABC winding pattern and delta connection with 14 turns, 0.6mm wire per slots, also 6 magnet sets attached to rotor with NSNSNS pattern (blue color print). Also I printed the same size motor with 12N 14P with the same wire and turns (white color print), as attached photos. The magnet sizes also are 15*3*2mm for white one and 15*7*2mm for blue one.
When I connect it to the 40A, 12v ESC, it is drawing 2A from my DC power supply unit and start to vibrating and turning a bit with continuous noise which you can hear in the attached video.
I also connected it to more powerful PSU and it starts to draw about 5A with the same symptoms but stronger.
I checked the winding directions and points of delta connection, and also polarity of the magnets many time but no luck.
If you need I can also share you the SolidWorks drawings.

Recodred Videos:

Any Idea?

Thank you in advance.

 

[Lordcx]

If you have access to a CNC laser cutter, you could cut out thin steel laminations with the same cross section of your stator. These could be stacked-up to make a proper stator. Magnets glued inside a section of steel tube is the simple, classic way of making an out runner rotor. You could use the 3D printer to make the bearing(s) and rotor support piece as in your original design.

Thank you for your reply, unfortunately do not access to the CNC. But , if the iron core is the case, I wonder how many 3d printed motors work as shown in youtube!!

 

[Lordcx]

With concentrated three-phase winnings in nine slots, you have built a stator for a three-pole motor, which makes no sense to me. The "14P" motor presumably means "14 pole"... which makes no sense either. How did you pick these configurations, and what are you using as a reference guide to motor design that would lead you to pick those?

Thank you for your reply, as I know 14 pole means 14 pieces magnet. Also the combinations of the slots and magnets are chosen based on the following table. Please correct me if I am wrong

 

[Lordcx]

It looks like you intended to attach a table, but it's just a link to imgur that doesn't show any relevant image. Where did you get the table? Is there a website with instructions for building motors that you are following?

I attached a table in jpg format. The source is the following webpage:
www.bavaria-direct.co.za

 

[Lordcx]

You're right, there are working 3D printed motors on YouTube.

You are totally right, I just wanted to make one for curiosity. The lack of iron is not logical to me too, but I did not think that much!

 

[Lordcx]

Okay, I see what they're doing. Rather than using windings for each phase is pairs mirrored across the motor, they have only a single winding per motor pole pair per phase.

Thank you for sharing great info. Actually I made this motor based on one of my outrunner motors which has the same slots and magnet pole, but I am not sure about the slot's wire turn numbers since I have not dismantled it, and it is working with the same controller but mine not.

 

[Lordcx]

My OCD is getting triggered - can you add a couple of skateboard bearings to the rotor shaft?

Can you please explain more what OCD is?