Description

This upgraded generator design is a major improvement over my previous 1:1 coil-to-magnet setup. The new geometry uses a tighter 2mm magnet gap, improved coil placement, and a more refined winding structure designed to transfer power more effectively under load. In early testing, one hand-wound 500-turn coil using 0.2mm wire measured 11 ohms of internal resistance and produced 1.8V RMS across a 15 ohm load while the DC motor input was only 1 watt. That comes out to roughly 0.216 watts of real usable loaded output from a single coil test, or about 21.6% usable transfer efficiency. This design is being developed as a scalable 3-phase, dual-sided stator generator concept, meaning the full version is intended to capture more magnetic field interaction through better phase spacing, tighter coupling, and improved load matching. More loaded coils will create more drag, but that drag represents mechanical energy being transferred into electrical output. This project is for builders, experimenters, and supporters who want to follow the real-world evolution of a compact 3D-printed generator design from raw testing to more optimized energy transfer.

Requirements:

1. 2x- 5mm x 2mm(shaft) Wheel Bearing
2. 1x- 2mm Steel Shaft
3. 12x 1cm x 2.5mm Neodymium magnets
4. .2mm wire

Note: If you double the size of this design you will achieve potentially 32x the power delivery under the same load conditions. This is where you step into off grid living. for the flange couplers i recommend using .2 nozzle for precision print.