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I designed and 3D printed a Brushless Direct Current (BLDC) motor, and used an Arduino to control the motor. All parts of the motor, excluding magnets, solenoid wrapping wire, and hall effect sensors, were printed with a Makerbot Replicator 2. The video shows the completed working motor.

This instructable is available as a pdf here along with cad files and the program for motor control.

Motor control program for arduino:

https://github.com/pi-track/3Dmotor.git

Feel free to use the files, comment, change the design, or do whatever you please with this!

Step 1: Materials and Tools

A 3D printer, an arduino microcontroller, and access to basic electronic tools like a multimeter, an oscilloscope, a power supply, and electrical components are necessary for this project. The complete list of parts and tools I used.
Tools

  • Makerbot Replicator 2
  • CAD software - Google SketchUp - MakerWare
  • Cordless Drill
  • Multimeter
  • Oscilloscope

Mechanical Parts

  • PLA plastic
  • ~100 meters of AWG 26 copper magnet wire for solenoids
  • 8 X N48 1/2 by 1/8 inch neodymium disc magnets

Electronics

  • Arduino Uno Breadboard - connection wire
  • Alligator Clips
  • 12 V battery supply - 8 AA batteries in series

Components

  • L6234 3-phase motor driver IC
  • 3 X SS411A Hall Effect Sensors
  • Resistors
    • 3 X 120 kOhm
    • 6 X ~400 Ohm
    • 1 Ohm
    • 100 kOhm Potentiometer
  • Capacitors
  • 100 uF
  • 330 nF
  • 100 nF
  • 10 nF
  • 2 X Diode

Table 1 shows the cost to build the motor. Electrical components such as resistors and capacitors were not included as the cost was negligible relative to the total cost of the motor. The total cost to build the motor, excluding the Arduino microcontroller and the batteries was $27.71. It should be noted that cost reduction was not a top priority, and optimization could result in a reduced cost of production.

Excellent sir, well done indeed!
<p>Hi Pitrak,</p><p>it's interesting to prototype robots with specific sizes of motors. I would like to test it but the link to the ZIP file with pdf and 3D files is broken.</p><p>Please could you send a new link to the archive?</p>
<p>I updated the archive link location. </p><p>Here it is: http://patrickeells.com/3DPrintedMotorFiles.zip</p>
<p>Thanks. I'll start to print one this week.</p>
<p>I had this crazy thought:</p><p>I wonder if the coils for the motor could be created by printing a pattern on paper with conductive ink and then winding the paper into a tube?</p>
<p>well done, it's beautifull. </p><p>I'm an electro technician from Belgium with a Velleman printer K8200. I also programm AVR 's.</p><p>I use Autodesk Autocad to design my printings.</p><p>So I also want to make such a motor , I have some ideas for improvements in the design to.</p><p>Can you contact me at my e-mail ?</p>
<p>Truely awsome, hats of to you my friend, How about you follow this up with a stepper motor design to replace a NEMA 17 the entrie RepRap 3D printer community would be indebted to you forever :-) </p>
<p>I just want to say thanks for being a pioneer in DIY motors. When I looked into this months ago, there was next to nothing available for anyone who wanted to design their own motor. Thanks for putting this out there!</p>
<p>Great job, this is a good example of where 3D printing is going. This type of &quot;on demand&quot; printing is going to change how industrial repair and logistics will be done in the future. </p>
awesome!!! hand made motors rules!!!
wonderful project ..though little complex in mechanical but in general a nice and lovely
<p>I agree, I would love to simplify it further in the future!</p>

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