3D Printed Brushless Motor: From Design to Test Flights

In the world of DIY projects and innovation, creating a 3D printed brushless motor for an RC plane is a thrilling endeavor. Recently, a designer has shared a project where a 3D printed brushless motor and propeller were successfully mounted and tested on an RC plane. Let's delve into the details of this project and explore the process from design to real-life performance.

Designing the 3D Printed Brushless Motor

The 3D printed brushless motor in question follows a three-phase OutRunner concept. It consists of three primary 3D printed parts:

Stationary Piece: This component includes essential features like ball bearings and screw holes for easy mounting on a car or a plane.
Stator: The stator houses annealed copper wires wound with a specific pattern in slots for efficient functionality.
Rotor: Featuring 12 neodymium magnets fixed on the shaft, the rotor spins, encloses the stator, and drives the propeller or gear.

All STL files for these components are freely available for download, accompanied by detailed printing and assembly instructions on MakC.

Testing the 3D Printed Motor and Propeller

Initial Findings and Power Measurements

With promising measurements indicating a continuous power range of 70 to 90 watts without overheating, the motor showcased its potential. Understanding that take-off demands maximum power, the designer estimated a ground power output of around 150 watts, offering a substantial performance boost.

Propeller Adjustment for Optimal Performance

To ensure compatibility with the 3D printed motor, the designer experimented with different propeller configurations. While the initial three-blade propeller drew 12 amps, the revised two-blade propeller with reduced pitch showed improved performance, drawing 9 amps at 12 volts and reaching a rotation speed of 8,300 RPM. This adjustment aimed to optimize power consumption and balance for safe operation.

Test Flights and Challenges Faced

During test flights, the RC plane encountered challenges related to weight distribution and stability. Despite modifications to the motor mount and weight adjustments at the nose, the plane faced issues with a tail-heavy construction, leading to uncontrolled flight behavior and eventual crashes. These experiences highlighted the significance of center of gravity in RC plane design and the impact it has on flight dynamics.

Conclusion and Future Possibilities

While the test flights revealed some challenges, the overall performance of the 3D printed motor and propeller indicated suitability for RC planes weighing up to 500 grams. The insights gained from this project serve as a valuable foundation for future experiments and improvements in RC aircraft design.

Get Involved!

Considering the open availability of STL files on MakC, enthusiasts and innovators are encouraged to explore their own experiments with 3D printed motors in RC applications. The potential for creativity and exploration in this domain is vast, offering a platform for individuals worldwide to engage in similar projects and share their experiences.

Meta description:

Exploring the design and test flights of a 3D printed brushless motor for RC planes. Discover the process, challenges faced, and future possibilities in this innovative project.

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