Making A Press Mold - Axial Flux Stator Casting

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Check out my latest project: • Build An Electric Moto...
Hey guys! Just a quick video today, showing how I made a press mold for casting an 18 coil axial flux stator - or showing why I prefer using vacuum injection instead. I built the turbine back in December, but my guy wires are now froze in a few inches of ice, so I probably won't get to install it until spring. In the meantime, I thought I'd share the press mold with you. It doesn't make a perfect bubble free cast, but it's easy to make, can be used multiple times, and does a reasonable job for DIY turbines. Links for the materials used to make the mold can be found below.
If you like these smaller projects, let me know in the comments and I'll try to publish more of them between the big projects to help fill in the gaps. With that said, keep your eyes peeled for an electric trike. As some of you already know, Grepow is generously sponsoring the build. I've been working on it and another big project on the side, but I'm not going to reveal that one until the trike is ready ;) Some really cool projects are in the works, so stay tuned!
Learn how to design a wind turbine from scratch with the Wind Turbine Design Guide:
www.resystech.com/the-diy-win...
Materials for the mold:
RTV silicone:
www.ebay.com/itm/RTV-PLATINUM...
Polycarbonate cover:
www.ebay.com/itm/POLYCARBONAT...
Toggle clamps:
www.ebay.com/itm/GH-225-D-227...
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Опубликовано:

14 янв 2020

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Комментарии : 75

@JamesBiggar 4 года назад

Check out my latest project: ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-yXQnydST9fw.html If you're interested in learning how to design your own turbine from scratch, PROPERLY, then check out this link: www.resystech.com/the-diy-wind-turbine-design-guide

@franzhugosandoval9746 4 года назад

Cuanto W entrega de energía?

@46B3x2you 3 года назад

Thank you so much. Keep it coming. i'm blown away with how much you know, how well you present it, and the fact that you're willing to share it with everyone. I will be following this link for a long time.

@douglasharley2440 4 года назад

your content is always amazingly interesting...much thanks!

@bluheat007 4 года назад

Awesome video. Really cant see the issue, but you did and know how to fix it. I have learned alot frome your videos.

@thomasmoore4576 4 года назад

Thanks man that's going to help me make a better stator love your video

@JonOffgrid 3 года назад

that,s grate James you got it down pat now cheers

@ThePunitiveDamages 4 года назад

Awesome, Thanks 🤘

@441rider 3 года назад

I have been making 3d printed plugs for molding this is great info,

@ppipowerclass 4 года назад

Man, I'll have my new garage up ( hopefully ) by this summer and I can finally get to making this stuff!

@AlekseyCamodelkin 4 года назад

Good video

@jagatsaran794 8 месяцев назад

Very good helpful for un employed youth and also fight pollution thankyou

@vistanationrockafellaz 3 года назад

wow awsome

@igorkvachun3572 2 года назад

Yes stator 👍⚡

@Panikkarson59 3 года назад

I have made a permanent magnet generator following your videos. I am avtually trying to make it pedal powered. Can you help me with calculating the number of magnets and coils required, once we know the rpm we can manage, trying out different gear options?

@carromacumba 4 года назад

🏆Excellent!!💎Big like!!🏆

@jessemabee2488 3 года назад

Hey. You do some really cool builds. Question. Do you know of a grid tie in inverter that could handle your wind turbine design??

@Rioderixxx 3 года назад

Can I explain more what, where and how to enter in the calculator? It needs 2000-2500w, wheel speed 200-250rpm, 21 coils with 1.6mm wire. Ioe of windings, with the coil template 5cm inside and 2cm wide?

@andyl7935 4 года назад

Nice demonstration. I like the inclusion of center holes in the coils for cooling . What diameter are the mag rotors for this project and what size/ strength magnets?

@JamesBiggar 4 года назад

Thanks. The rotors are 16" in dia. and the magnets are N50 1/2x1x2" block (CMS Magnetics, magnet4sale.com)

@kieranmccarthy7261 4 года назад

Does it matter if the individual coils touch?

@TheBillythekid2010 4 года назад

It's always going to trap bubbles without a way of releasing air out of it. I watch these guys making epoxy tables with all sorts of decorative inclusions. The Cure time of the epoxy is a lot longer and allows for the air bubbles to rise and they use a spray or heat on it to release when they come to the surface. So they pour half of the mold with epoxy, use the spray to release or either heat to release. Then they wait a little bit and then they pour a little more until the mold is full. Crystal clear every time...

@JamesBiggar 4 года назад

Yep, blowtorch pops those epoxy counter top bubbles pretty easily. We've installed a lot of them at work. But we don't cover those and put them under pressure to make them as thin as possible - that's the problem with the press mold. The exit hole in the polycarb cover will allow some air to escape with the excess resin, but unless a person picks the mold up and starts thrashing it around, then most of the bubbles that are trapped are going to stay there - or they're going to knock their coils out of center in the process lol. That's why I like my vac injection mold with the degassing chamber to remove bubbles from the resin before it even enters the vacuum. I'll be setting this one up the same way, when I get a new pump.

@TheBillythekid2010 4 года назад

Here's a channel I sub to and thanks for sharing 😃 ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-AsopsTPbnwM.html

@TheBillythekid2010 4 года назад

@@JamesBiggar where did you get the polycarbonate film? It's not in your links. Thanks Buddy for making the creativity flow, LoL 😃

@JamesBiggar 4 года назад

@@TheBillythekid2010 I bought a roll of it on Ebay a couple of years ago for a project that I didn't end up doing. I can't find a link for it anymore, and didn't end up using it for the mold anyway, so I didn't put it in the description. But it's just a basic Lexan polycarb film, somewhere around .01-.02" thick. Similar to this: www.ebay.com/itm/Polycarbonate-Film-Clear-015-15-Mil-x-24-x-24-2-Pcs/121716161879?hash=item1c56d93d57:g:USgAAOSwehdc6Jh6 I didn't use it because I wasn't sure how much heat the resin would generate, with it being a larger than normal stator. Based on experience, thin polycarb distorts pretty bad when even a low grade heat's applied to it, so I didn't want to take the chance. If a person spread a super thin and even layer of contact cement between it and the plywood, then that might work. But if you're going to spend the money on film and adhesive, you might as well just spend it on a piece of HDPE or some other low cost plastic sheet to replace the plywood altogether. 1/2" thick with a few small supports underneath should work fine.

@JamesBiggar 4 года назад

@@TheBillythekid2010 Cheers bud!

@oh8wingman 4 года назад

The coil at about 12;30 is out of alignment with the others.

@SD_Alias 4 года назад

What a giant afford! Are you an engeneer? Or is all self taught? So good to watch…

@MARS-fi6wq 4 года назад

Nice job, u're Amazing. Too Bad for the coil right to the connection ports which is miss-aligned.

@JamesBiggar 4 года назад

NAILED IT. You're the first. Let's see who else notices it...

@unogazzy84 4 года назад

@@JamesBiggar Missaligned how? I don't know anything about these type of things so I have literally no idea.

@JamesBiggar 4 года назад

For the best concentration of magnetic flux into the stator and thus the best performance from the generator, the magnets need to line up over the coils accurately in a specific way. Ideally, the outermost portion of the inner perimeter of the coil (if that makes sense) should line up with the outer edge of the magnets on the perimeter of the rotor. If the magnet edge extends beyond the inner perimeter of the coil, then the windings that are covered by the magnets won't be energized near as much if at all. If there's a space between the edge of the coil and the edge of the magnet, then that's wasted space that could have been filled with copper. Check out the link in the end card at the end of the video to see how an axial flux generator is built for a better understanding of what I'm talking about. I also have a design guide available on the website that explains everything in detail.

@alibro7512 4 года назад

I've seen (make that made 😯) a lot worse and I bet it would still make a good (if not perfect) stator.

@unogazzy84 4 года назад

@@JamesBiggar Thanks for the reply. Can you or someone else link me to that design guide? I can't find it.

@Traderhood 3 года назад

Maslow CNC?

@dopechannoodles9791 4 года назад

Total cost?

@441rider 3 года назад

The coils are not consistent gap from rotor edge?

@JamesBiggar 3 года назад

You got it

@441rider 3 года назад

@@JamesBiggar Cool, it's the obvious we miss sometimes. Nice to see innovation well and good on the east coast! I may have ev motorbike questions soon. LOL! Just crashed my 52 Roadmaster 2wd 1500w bicycle into chain across a path so have planning time. Want to build a 10kv converted rz350 or 250 ninja.

@BenMitro 4 года назад

Just hazard a guess - the wiring doesn't come out for connecting to?

@thunderstruck1078 4 года назад

That's why I thought too, having seen the leads trapped inside, but aren't the brass things on top used for that?

@BenMitro 4 года назад

@@thunderstruck1078 I thought that might be the case too, but they are buried in the resin I think. I guess you could drill them.

@JamesBiggar 4 года назад

The brass nuts can certainly be drilled and tapped, np

@oldtimeengineer26 4 года назад

4 coils from around 11:45 to around 1:15 out of alignment and the pole holes at the top look out of alignment

@JamesBiggar 4 года назад

Got distracted with the mix and forgot to hit record. Realized the camera wasn't on, messed around with it, forgot to center the coils up in the mold before covering it up. DOH!

@JoseSilveira-newhandleforYT 4 года назад

@@JamesBiggar That's too bad... To share the pour with us you ended up scrapping expensive materials and man-hours. I almost feel guilty for watching it. Is the misalignment severe enough to scrap the stator? It seems most of the coil will cross the magnetic flux. Or is there a mechanical alignment of the holes also involved?

@JamesBiggar 4 года назад

No worries! It's my own fault, and the stator's still useful. But ideally the outermost portion of the inner perimeter of the coil (if that makes sense) should line up with the outer edge of the magnets on the perimeter of the rotor for the best efficiency. If the magnet edge extends beyond the inner perimeter of the coil, then the windings that are covered by the magnets won't be energized near as much if at all, contrary to popular belief (due to the pole configuration and field line structure). If there's a space between the edge of the coil and the edge of the magnet, then that's wasted space that could have been filled with copper. This is why the best magnet shape for this coil shape would be a wedge (if they were affordable), because it would conform to the inner profile of the coils better. The inner profile of the coils should match the shape and dimensions of the magnets used. I accept a slight compromise in efficiency for affordability by using the rectangle magnets with tapered coils, but the widest and longest dimensions of the coil's inner profile is the same as the mag's (1"x2"), and the tighter end of the coil is roughly half the width of the mags. This lowers the efficiency slightly, but not enough to negate the cost benefit. However, this particular stator is a bit to out of whack for showing off performance on RU-vid. It's alright though, I've been stocking up on copper over the years. Sh!t happens lol.

@JoseSilveira-newhandleforYT 4 года назад

@@JamesBiggar Thanks for clearing that :-)

@blackjackaxialfluxturbines4174 4 года назад

Hey Buddy, hate to tell you that Missouri Whinning and Stumpidness has got my channel taken down, TheBillytheJack2010!! It has been up 4 yrs now and has a new video on the Axial Flux 12 coil I'm building. So please sub and like my videos, please... Heres a link: ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-Jo8967xP8GE.html&lc=z22gxr4hhovsyeqtm2hd0s2yq3pcpphhtjgmutyvvj00u00c2

@snipersquad100 4 года назад

No bolt holes to attach to the turbine body.

@heronsilveiralima1994 4 года назад

Do que é feito a bateria de tesla? Como é sua fabricação?

@rajgondakoik7140 2 года назад

Sir coil turns ohms magnet quantity

@JamesBiggar 2 года назад

The video is about making a press mold, not wiring a stator. Generator design depends on application and power requirements. See appropriate videos for more info.

@oggymorowse4984 4 года назад

What's wrong with this stator?

@JamesBiggar 4 года назад

@@nordishkiel5985 Nope, but something IS out of alignment

@chrisd1828 4 года назад

Looks at the coils like numbers on a clock. See anything different at around 1 O'clock? It moved close towards the center, where the others are spaced away from the center.

@salihoval3723 3 года назад

You did not let any wires before molding ✌🏻

@JamesBiggar 3 года назад

You do not make sense ✌🏻

@rafaelsuleymanov7956 4 года назад

why don't you make a CNC?. so your job will be easier.

@JamesBiggar 4 года назад

Because building a CNC is a lot of work, just to not use skills that I spent a lifetime honing ;) If I were a newb and not a journeyman carpenter, or intended to mass produce something, then I would opt for a CNC (or multiple machines), for sure.

@JamesBiggar 4 года назад

...in short, because I enjoy woodworking :)

@rafaelsuleymanov7956 4 года назад

@@JamesBiggar I didn't know you were a carpenter

@JamesBiggar 4 года назад

@@rafaelsuleymanov7956 No worries, I figured as much. There are a lot of carpenters and woodworkers on RU-vid with CNC machines, so it's not an unreasonable question to ask.