Simple Electric DC Motor

This is a fully functional 3D-printable model of a DC electric motor, designed for educational purposes and engineering enthusiasts. This project brings physics to life, demonstrating the principles of electromagnetism, magnetic field interaction, and the mechanical function of a commutator.

The model is optimized for 3D printing and manual assembly, allowing for a clear view of all moving parts in action.

Key Features:

• Functional Design: Includes a dedicated rotor, stator with magnet slots, and a tactile commutation system.
• Educational Tool: Perfect for teaching Faraday’s Law and Fleming’s Left-Hand Rule in a classroom or home setting.
• Bearing Support: Designed for 16mm outer diameter bearings to ensure smooth rotation and minimal friction.
• Modular Stator: The frame allows for the insertion of up to three high-strength magnets (N52) on each side to experiment with torque and speed.

Bill of Materials (BOM):

• Magnet Wire: Enamelled copper wire (~0.22mm diameter). 400 to 600 turns are recommended for the rotor.
• Magnets: Neodymium magnets (N52 recommended).
• Shaft: 5mm diameter stainless steel rod (approx. 200mm length).
• Bearings: 2x 16mm OD bearings.
• Commutator Plates: Small sections of 22mm copper pipe or conductive copper tape.
• Power Supply: DC Bench power supply or battery pack (works well at 12V).

Assembly Tips:

• Rotor Prep: Ensure you sand the ends of the copper wire to remove the enamel insulation before connecting them to the commutator plates.
• Alignment: Use the built-in guidelines on the rotor to align the copper plates perfectly for timing.
• Polarity: When installing the magnets, ensure the North pole faces inward on one side and the South pole faces inward on the other