3D Printed Turbo Impeller VS Dyson Motor 

The fact that you can actually 3D print an impeller rotating at such a speed with a plastic is insane

The dyson's impeller is used in a vacuum that sucks up dust and the one this guy made creates dust and efficiently spreads it around everywhere.

For balancing rotating parts like the impeller, you could use the method my father used to balance his model aircraft propellers. He had a shaft the size as the center hole in the propeller. The shaft came to close to a needle point on either end and was carefully balanced at either end on a metal plate so that it would spin as freely as possible. The propeller was then gently spun and allowed to come to a rest. If the propeller ended up one blade down, that blade was marked and spun again to see if the same blade ended up pointing down. If was the same blade again on the next try, a little was shaved from the end and the whole process repeated until it seemed to be random as to which blade was pointing down.

Ya know Daniel, I've been subbed to you for a really long time. You were a kid back then and your videos were kind of cute. Kid makes cool things out foam cuz he is a kid and has no money but here we are all these years later and honestly you are a true gift. Everything you make is interesting even your ad/sponsor parts of videos. So I just want to say thank you for all you do.

Knowing a little about high rpm’s, it is ALLL about balance. It’s quite impressive to get such results in a home lab setting 👍

Today we are going to see how loud, inefficient, and unreliable we can make an impeller

This is really SOMETHING! Thanks soo much for bringing us this, Daniell🥳🥳🥳

You certainly have Dyson beat in the "explosive potential" category. 😂 The moment you talked about the close clearance and high RPM, my first thought was "it's about to explode".

The motors seem to need a thrust washer/bearing as the axle seems to be pushing out which pushes the impellor into the house. You can see 13:00 after the impellor explodes that the axle retracts when the motor slows.

I used to do motor R&D for Shark Vacuums. Your rate of improvement is great and watching this took me back to some of my favorite engineering. Love your work.

The Dyson vacuum motor is aurally a little different from a typical brushless motor. It is a switched reluctance motor if I remember right, they are good at reaching insane speeds.

Daniel this is some awesome engineering! Love your iterations and fearless testing. And your very well rounded skills in Cad and 3D printing. Your steadily increasing physics, systems and shop knowledge help you to quickly recover and test new ideas. Love it, man!

"digital motor" gotta love the marketing department and their brilliant naming ideas

Instead of a scroll housing I'd suggest taking the air all around circumference back over the motor for cooling, also exhausting in same direction as intake airflow should give better thrust. Early gets worked this way as do most model gas turbines now

Great work! It looks like your impeller spins the wrong way for the thread handedness, which if true is the reason for a number of the failures: The impeller is wanting to spin the nut off the motor shaft at higher loads. Easy fix is to print the mirror of the impeller, so that it runs in the opposite direction, and reverse the motor rotation. When I have dynamically balanced things in the past, I’ve used a flexible beam (thin long bar of aluminum) that I can clamp up on to vary its length, made a motor mount to attach to it, and put a dial test indicator (DTI) on the free end. Gives extremely precise measurement and repeatability for balancing.

Your turbine impeller exploding is due to unbalanced parts and large tolerances on the interfaces. You need to do two things to address this: 1) balance the rotating assembly, and 2) ensure that there is no movement of the impeller on the shaft. 1) is relatively easy: you construct a balancing spindle as described by another commenter. A precision shaft that the impeller mounts to, which tapers to needle points on both ends. The unit is suspended between angled plates, allowing it to spin freely. Then the whole assembly is spun and the downward facing blades marked. Repeat this cycle to ensure that the same blade is heavy, and then shave until the blade down is not repeatable. 2) is harder because of the materials you're working with and the parts. The threaded shaft on the motor is the main problem. Even if you print a tight fit on the impeller, if it is unbalanced at all then the forces will be amplified by the extreme rotation and cause the plastic to dig into the threads of the shaft, thus introducing slop. This slop allows more movement which allows more vibration and more slop until the whole thing goes boom. To eliminate this, you will need to sleeve the shaft with a hard metal (not brass or copper or aluminum, regular steel should be fine doesn't need to be hardened), and then bring your impeller bore to final size using a reamer instead of relying on the printers finish. Be sure to do the reaming before balancing. You may want to press in a hard bushing/mount on the impeller instead of sleeving the shaft, but again take care to ensure a very close fit on the shaft. You can keep using the nut clamp system, just under size the length of the sleeve so that the nuts still clamp the impeller directly. If you're using washers, you need to ensure a tight tolerance on the washers and consider balancing them as well. A final practical matter is airflow and cooling: you probably want to direct airflow over the motor for cooling. This will probably cost some thrust, but is critical for motor longevity especially at the high power levels you are using. Looking forward to the next installment!

This is EXACTLY what I've been looking for, an insanely high pressure blower fan that I can 3d print cheaply. Thanks!!!

I also think there's something to be said for the plasticity level of the impeller material. After awhile the friction I'm sure causes material warping which expands the impeller and pushes it against the snail housing walls. Similar to blasting a skateboard wheel with compressed air/water and it expanding.

you did an amazing job with these kind of things so far. You definitely showed somebody like me who is an engineer about these kind of things how difficult it really is to make these kind of things efficient enough

Your ability to crank out worthy content is mesmerizing! Thank you! It’s my hope it continues to remain more on the enjoy side than the work side for you:)

The reason why they are using only 2 pole pairs is likely also due to the electronic commutation limit. With an excess of 100000 rpm many cheaper controller are not capable of commutating motors with a high pole pair count. 100000 electronic communications a second is a common limit of those controllers. And because they practically have no load on the motor, it’s forgivable to only have two pole pairs.

The higher speed listed for the Dyson is with the inlet blocked. This creates a partial vacuum, which means less resistance on the impeller => higher speed

It's fun to see how you and great scott differ in procedure. The hammer to open it in particular 😄

Last year in my design internship at a quantum cooling startup I got introduced to onshape. Coming vom Rhino7, which of course has so much functions and his hard to master, I quickly found a liking to onshape. The fact, that you can open, view and edit your file from almost any device from anywhere you can imagine because it's cloud based is so tremendous. Plus in a company you can manage projects and put single files together in a huge asssembly is amazing. The company also had formlabs Form3+ printer. Its a gamechanger compared to my own ender 3v2. No hazzle, no tweaking. The print always came out perfect and smooth.

Really cool video. Thank you for sharing the cad file, was cool and helpful to look through and see how you made the it, especially the blades. : )

Dyson fan multirotor seems eerily close to fruition 😮

I like that you're willing to take things you've worked hard on and test them to destruction.

Thank you for doing what you do never stop making these videos.

Ive been wanting to make one of these for a project, this is amazing

How cool. You are one of the few show ng how functional prints can be used for a myriad of applications. Well done keep it up I want to see lawn mower v2

13:13 Just look at this beautiful vortex just spiraling in. Forming and dissolving. Nature is so beautiful.

This video had some really cool shots!

Looks like it could be a great electric turbo for a car, bike, boat, or lawn motor... Also, what a sexy 3D print project!

Holy CRAP! The way this first iteration blew itself up was just... my reaction was like, "WHAAAH!"

If you want pressurized air to be more efficient you should check out the inside of a compressor housing on a turbo. They don’t use director blades to force the air in the direction of the outlet to increase velocity. It will help a lot.

The fact that it didn't blow up within 5 seconds impressed me!! I don't think I could ever make something spin that fast and not go pop!

Videos like these and the influence of my dad is why I'm getting into engineering lol

It's easier to remove support material before curing 👍 Also, using nyloc® nuts for the motor will keep them tight under vibrations

2:00 about KV rating: KV is for motor RPM what pitch speed is for a prop: when a prop is going at it's pitch speed, it's no longer producing ANY thrust. Same with a brushless, if it's going at it's theoretical RPM (KV x Volts) it's no longer producing ANY torque. When calculating the useful rpm of your motor, you have to multiply by a 'slip' factor: typically around 0.75 or 0.8 depending on alot of things ; ) So your motor should give you 118 000 * 0.75 = +- 90 000 RPM

I love the how to basic style of deconstruction on the vacuum

I can’t imagine the prices of those formlabs resins. How long does 1 Liter go for you? How much did the impeller take?

You can use air flow meter from the car, to measure air mass.

"it's loud, inefficient and likely to explode" you mean it's perfect, thanks for the video!

The snail housing: i only know of the ones that have a very small outer diameter directly behind the exit (rotation wise). Due to the same diameter much of the air gets just spun around in circle until the centrifugal forces prevent it from making the turn. Hmm... thats probably the diffrence, between max flow or max pressure on the outlet. Yours is probably set up for pressure. You can try to balance the impeller statically by mounting it to a thin needle and place that on a post. That should reduce friction and should turn the impeller with the heavy side down.

"I used the built-in lathe" got a good chuckle from me. I'm still watching, just wanted to mention this.

Amazing, almost feel like putting on some safety goggles just looking at the high RPM testrun.

Love the pcb way ad read while wearing the on-shape tee-shirt. Hitting two birds with one stone

Cool watching your channel grow!

I do love this video which is awesome but not quite far to compare thrust on a dyson motor which is strictly designed for being a vacuum and not for pushing air out so its really not a far comparison, but they also are designing it for better battery consumption as well. I am so impressed you were able to make a 3d printed impeller spin that fast without vaporizing, that's incredible

Cool beans. I have 18 partially completed projects, but I think you have me beat in terms of competed & more to come.

Engineering, with comedy, is always the best form of entertainment! Thanks again Daniel, I always enjoy your content. Bye. :)

9:29 two birds on a wire, one tr- Bird:AAAAAAAA

Seems like you might have significant losses due to the design of your impeller housing. Normal centrifugal pump housings have a volute that gathers the air flung by the impeller to guide it out of the pump. Your fully toroidal housing might be losing a significant amount of thrust just swirling air around inside... Also, those internal guide vanes probably just represent losses to the airflow coming off the impeller - the angle of the outflowing air should be controlled using blade angle on the impeller, not external vanes. Would be interesting to see the effect a refined housing has on performance!

"It is loud, inefficient, and it is likely to explode." I think with that you've offically crossed the line into Mad Science.

That yellow turbine looking sus

you made a mistake when you made the impeller blades flat. they have a three-dimensional shape, thickening towards the base

The howtobasic-style hammering at the beginning made me chuckle :D

Really great effort, the balancing of high speed parts seems to need computer accuracy to be successful. Dyson may have a few more people, and a lot more money, to develop these systems, but I LOVE that you gave it a shot !!!

8:13 “This video is sponsored by PCBWay” he says while wearing an Onshape shirt

You could probably use a bearing closer to the impeller. In the car world we would use a run out dial indicator and make sure the back side and all the tips of the blades are spinning within .001 and if your outside rear edge and all the tips of the blades are running at .001 it should be balanced. Adding hot glue will interfere with the blade effectiveness so just try taking of smooth layers on the meat or within the central part on the back of the impeller to balance just a lot of back and forth on the micrometer

Another great video, thanks

Best ad ever! I wanted some pcbs printed.

this is so insane lol. love it . your content is always next level

I never thought about the axial thrust load on the impeller shaft when it's sucking an air. There has to be a force pushing on the impeller blade. That's awesome

Thumbs up for this interesting video. It must be hard to come up with new ideas that hold the interest of the many and this was one that did. Good job.

"Loud, inefficient, and likely to explode" - that just makes it better!

One way of using the dyson impeller is making something more like a jet engine, you might get more of a ram effect and air multiplication if the exhaust is made right

Congratulations on getting 3 different sponsors in one video

3:10 I got a free sample of formlabs printing capabilities a few years ago. It was a sample of filament that can be used for springy things

Get PCBWay to metal print an impeller for you! Awesome video

You should start doing a parody of Dyson commercials in your videos any time you cover one of their motors. LOL

whoo! Look at that! *GOES WILD WITH A HAMMER*

Switched Reluctance Motor : Dyson DMT

You Are Amazing! Thank You.

"Your going to put your eye out!". Wonder Years. Lol Red Rider shot gun.

You've come a long way from that kid bashing foam in the school yard! Right on!

If the motor was on the intake side with larger inlet that allows / forces the airflow around the outside of the motor it could cool itself down while it draws in the air. 🤔😉👍 Those resin printed parts look absolutely amazing.

5:34 Impeller has left the chat.

have really enjoyed your videos thus far...cool colab with the plasma channel...

Vibration is definitely a huge thing to deal with... You have to balance the impeller for static and dynamic vibration... But one more thing to consider is physical expansion due to high centrifugal force... Materials tend to expand at such high RPMs/Forces...so you have to adjust you tolerances accordingly.

That opening totally made me think I was watching Howtobasic lmao

Very cool! How did you design the impeller blades and their configuration?

Broooo, you should make a “hundred thousand miles test on rc cars” but with higher quality cars. That would be awesome, I love that video

Awesome work.

Amazing!! A question: from which Dyson model you have extracted the motor visible at 11:38? Seems very easy to run with original controller, differently from some other models that are more complicated.

Dyson uses a reluctance motor according to my research. Rather than permanent magnets, the rotating core just has a magnetic material like iron that seeks to center itself in a magnetic field. It works like a familiar linear solenoid but in rotation. There is no field reversal in the iron so this supposedly gives an RPM advantage.

You can cut down on vibrations a bit by mounting the impeller differently. Threaded rods and nuts are very imprecise, using the nut to center the impeller will result in it being off center and at higher RPMs it will just vibrate like crazy. Minimize the impellers runout (how off center it is) and it will make balancing it much easier.

Fun thing. Being Finnish the KV actually works directly in Finnish language as "kierrosta (rounds) voltille (per volt)"

Wow Never new that pcbway could Machine big parts

HowtoBasic will have a long lasting legacy on youtube

Well to be fair part of that weight for the dyson includes the speed controller etc.

Guy almost turned into buttered side down at 0:05

"Oh, look at that..." * *INTENSE HAMMERING* *

"It didn't blow up! Woohoo!" - RCTestFlight, 2024

I think you could improve the results with a better snail housing. The radius should increase closer to the exit nozzle. (so the axle of the impeller is eccentric to the housing, while in your design it is nicely centered)

"The built in lathe" 🤣🤣🤣

your videos are a treat

Please, please do a deep dive on magneto hydrodynamics… your the only one that will go down a rabbit hole and come back with answers!!😊

That was the best and scariest intro I’ve ever seen.

I used to work in a Turbo shop, and you can properly balance an impeller with a prop balancer. You would know the ones: they magnetically levitate the Prop/fan on a shaft for almost zero friction. Grab one of those to balance your impeller!