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Complete Downloadable Kilowatt Wind Turbine—just add magnets & wire!

by haydnv, published

Complete Downloadable Kilowatt Wind Turbine—just add magnets & wire! by haydnv Aug 18, 2012

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Description

This is a wind turbine designed to output 1KW under optimal conditions. It uses a 3D-printable generator, thing:28762 .

Recent Comments

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Re. blades: you can just cut them out of a plastic plumbing pipe diagonally, therefore you get cheap blades that can be easily replaced in overwind accident.
Take a look at the Rostock printers...

youtube.com/watch?v=SjA455e0Mig

youtube.com/watch?v=OiN8wNyLdTI

That bottle is 350mm. If you make the legs of your Rostock tall enough, you can make some very tall objects
Hi, I write for Popular Mechanics and I'm working on a story about Thingiverse and 3D printing scientific equipment, in which I am going to mention this lovely turbine. Could I call or email you to get your comment on this device in particular and the practice of open source hardware sharing in general? My number is 212-649-2973 and my email is [email protected].

Thanks!

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Instructions

**WARNING: BUILD AT YOUR OWN RISK.** This wind turbine can be dangerous and has not been fully tested.

You can get the source OpenSCAD files from my GitHub repo: github.com/haydnv .

You'll need:
- 1 axial flux generator, thing:28762
- 3 blades cut from 3mm aluminum
- 1 vane cut from 3mm aluminum
- 1 mount_base cut from 10mm plastic or acrylic (can be printed but not by most desktop printers)
- 1 mount_vertical cut from 10mm plastic or acrylic (likewise)
- 1 pole_cap, printed
- 1 rotor_cap, printed
- 1 1" pole at least 1 meter tall
- 1 thrust bearing, 45mm ID x 65mm OD x 15mm high
- 1 tube of gasket sealant

To build:
- Build a generator per thing:28762
- Glue on the rotor cap with gasket sealant and allow 2-3 hours to cure
- Insert the tabs of the vertical mount into the base of the mount
- Secure the mount by snapping on the vane
- Connect the mount to the stator of the generator with the pins; thread a small piece of wire through the hole on the mount side of the pins to secure.
- Place the pole_cap on the pole and the bearing on the pole_cap
- Place the turbine on the bearing
- Insert the blades into the rotor_cap with the flat (leading) edge toward you
Re. blades: you can just cut them out of a plastic plumbing pipe diagonally, therefore you get cheap blades that can be easily replaced in overwind accident.
Hi, I write for Popular Mechanics and I'm working on a story about Thingiverse and 3D printing scientific equipment, in which I am going to mention this lovely turbine. Could I call or email you to get your comment on this device in particular and the practice of open source hardware sharing in general? My number is 212-649-2973 and my email is [email protected].

Thanks!
oh also a question what's the wing span on those aluminum blades

?
The blades are each 1 meter long for a 2-meter swept diameter.
why can't it be printed by a reprap would like an explanation on that one

terramir
A RepRap has a pretty small (I think it's like 10x10x10 cm) build envelope, which is way too small to make the blades or the mount in one piece. With a larger 3D printer you could actually make better blades since they would be lighter and you could print them with an aerofoil curve instead of just flat, but the design calls for CNC-milled blades since that's the cheapest and most accessible option.
Take a look at the Rostock printers...

youtube.com/watch?v=SjA455e0Mig

youtube.com/watch?v=OiN8wNyLdTI

That bottle is 350mm. If you make the legs of your Rostock tall enough, you can make some very tall objects
KazW - in reply to haydnv
Very neat design, I'm going to see if anyone at my hackerspace is interested in this kind of thing, I'd love to build one. :-D

Side note... I suggest a bit of research before saying something can't do something, the standard Prusa Mendle build envelope is 20cmx20cmx10cm, on an i3, it's a 20cm cube. Only the huxley is unable to print this. ;)
haydnv - in reply to KazW
Great! Let me know if you run into any problems.

Forgive me for forgetting the build envelope -- I still do recommend you don't try printing the rotor or stator in one piece since the stator is 23cm across and trying to manage the magnets in a rotor at once is probably dangerous :)
Saved me designing this, thanks.
Design your own anyways. Games are copied every day, but it's the implementation details which make one game of the same genre of game better than another. Having multiple designs to build and learn from would still be very beneficial to the community.
Very cool! I love the idea of people with 3-D printers being able to make other technologies that can directly benefit themselves and their communities. We need a lot more renewable energy tech everywhere and this is a really nice way for people that want it to gut the costs. Thank you.

What is your planned testing program for it?
Unfortunately I only had enough money to build one prototype, which was damaged in a fall. It may be a month or three before I can put another one together
— I'm hoping at least someone here on Thingiverse will beat me to it though!
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