Many shapes and sizes

Wouldn’t it be great to make a motor with ideal properties for your application? Perhaps you want very high torque and low RPM, or vice versa? Perhaps you have a restrictive design volume, or maybe you have low availability of materials. For my dissertation, I conducted a board investigation into the feasibility of in house design and manufacture of brushless DC motors with printed iron/PLA cores by looking at the following.

• Ease of manufacture/design

• Output torque / speed

• Efficiency 

• Overall cost

I explored multiple motor designs to exploit different properties of the material and manufacturing process. Ultimately the motors were too low efficiency and time-consuming to be cost-effective and functional. Although with more time superior designs can be developed.