Introducing the newest revolutionary 3D printed motor. The 3-Phase Duo Stator motor- a true one-of-a-kind

Supplies

8x M4 L12 Screws + Nuts

4x M4 L25 Screws + Nuts

8x Neodymium Magnets – 25mm x 8mm x 2mm

3x Grey wire nuts

3x Shaft Collars 6mm bore

2x Bearings – 6mm x 19mm x 6mm

1x Steel rod – 6mm diameter, 10cm length

1x Blue wire nuts

0.4-0.6mm enamelled copper wire. 12 wires measuring 1.6 metres each

The above parts can be found on Amazon / Ebay

Prints

1x Base print

1x Top Print

24x Coil hold Prints

1x Rotor Print

1x Rotor Top Print

1x Simple case Print

1x Simple case close Print

1x Wire cover Print

The STL files can be found here for £5:

STL file 3-Phase Duo Stator motor・3D printer model to download・Cults (cults3d.com).

Step 1: Prints Plus Base and Top Assembly

Start with printing and cleaning the parts

Firstly the top print, insert one of coil holds into the slots in the direction opposite to where the bearing hold is protruding. Use a slot with a hole at the base of it/ towards the edge. Also make sure to leave 2 slots with holes at their bases ahead of the one you’re starting with and 3 slots with holes at their bases behind it.

You’ll need 4 strands of the enamelled copper wire, twist them together a few times

Insert the twisted wires through the hole at the base as described previously, in the opposite direction to the coil hold. The length of the wire out the hole should be approximately 10cm. Wind the turns anti-clockwise over the coil hold. Complete 6 turns.

Repeat the above to fill the two slots ahead of the one you have started with. Use a new set of twisted wire for each slot and hole.

You have now completed 1 of 4 sets. Repeat the winding pattern another 3 times until all coil hold slots are filled. Finish the phases off by putting the left over wires, after the completed final turns, through the holes at the ends of the slots described in step 2

Repeat all the same wiring sequence for the base print as well. The coil hold must be in the same direction as the bearing compartment is protruding. Refer to the images regarding how the coil hold and the base/top prints are assembled

Step 2: The Rotor

The rotor print –this has slots for the magnets, it’s a case of slotting them in. They should be alternating, North-South-North-South

Once all the magnets are loaded, clip the rotor top print into place, aligning the 4 holes on the rotor top with those on the rotor.

Use 4 of the M4 L12 to lock the rotor top and the rotor together

Insert a shaft collar into the rotor making sure the outlet on the shaft collar and the rotor top are aligned in order for you to be able to secure the rotor onto the shaft/steel rod later

Step 3: The Casing

Add a shaft collar to the steel rod, allowing for a 6mm space from the bottom for adjustments.

Add the bearings (6mm x 19mm x 6mm) to the top print and base print bearing slots

Secure the simple case print onto the base print using the 3x M4 L25 screws.

Put the metal rod with the shaft collar through the bearing on the base. The shaft collar should be at the bottom, acting as a stopper

Insert the rotor through the top, use the shaft collar on the rotor to secure it in place. The distance between the top surface of the base and the bottom surface of the rotor should be 13mm

Secure the top onto the case using 3x M4 L12 screws, use the metal rod through the bearing to guide it into place. Align the out wires for the base print and the top print (Please use the image for reference). Once the wires are aligned, add the top shaft collar onto the shaft.

Step 4: The Wiring

Trim the out wires of the top print to about 4cm, connect 3 of the terminals using the blue wire-nut.

Trim the base wires to approximately 10cm and apply the shrink wrap to them. You should have 3 terminals left on the top part after connecting the other 3 with a blue wire-nut. These will be connected with the base terminals they are aligned with. Put the 3 aligned base terminals through the 3 holes on the wire cover.

Once the 3 aligned base terminals are through the 3 holes on the wire cover, the wiring can be done. The wiring is as follows, base to top: Phase A(Base) to Phase C(Top), Phase C (Base) to Phase A (Top), Phase B (Base) to Phase C (Top). Use the 3 grey wire-nuts to close off the three connections.

Note: The enamelled copper wire must be cleaned, i.e. exposing he copper before the connections can be completed. Make sure to clean 10mm from the end of the wire, this should be sufficient for connection purposes.