Axial Flux Motor
CompleteWhy
Combat robotics demands motors that are compact, lightweight, and reliable under repeated impact, making a custom axial flux design a better fit than off-the-shelf options for spinning a weapon blade at high RPM. I also wanted many of the parts to be 3D printed to cut down on external procurement costs.
How
Designed an 8-pole, 6-slot brushless axial flux motor in Onshape with fully modular components, engineering the assembly so the interior could be quickly accessed and serviced without compromising structural integrity. The housing holds six miniature copper spools around a central shaft supported by bearings on both ends, with M3 nuts and screws securing the hexagonal enclosure. The rotor has 8 cutouts for neodymium magnets that drive rotation. Because the architecture is 3D printed, I can keep spare parts in stock in case the motor is damaged during testing.
Results
The final motor delivers high RPM with a lightweight, cogging-free architecture, giving the combat robot a fast-spinning blade while keeping maintenance quick and mobility intact. I am currently experimenting with different attachments to see which best fits my vision for the combat robot.