This experiment tested the limits of 3D printing in creating a motor for use in a 3D printer. The motor was constructed using 0.2mm thick layers of Carbon fiber and Iron particle PLA filament, assembled into eight separate dovetailing sections. It comprised exactly 363 layers, each with distinct laminations of carbon and iron. The design resulted in a 24V, 8-pole, 4-phase stepper motor.

The laminations in the motor were specifically designed to reduce eddy current losses and improve its magnetic properties. Following its assembly, the motor was annealed, coated with two layers of high-temperature ceramic enamel, and then annealed again. It was wired using 20 AWG wire, in line with its 24V specification.

However, unresolved issues with torque and RPM arose. Post-project, the stepper motor controllers were repurposed for a different application, where it was found that they were limited to 1 RPM. This limitation likely stemmed from their original design for a gimbal system. I used the wrong motor controller! I encourage others to continue this research, as despite the challenges, there is promise in a 3D Printed Motor.