Efficiency Takes Flight: 3D-Printed A2212 Brushless Direct Current Outrunner Motor Propelling Next-Gen Drone Deliveries

Drone-based delivery systems have gained traction in recent years as a promising solution for the efficient and timely transportation of goods. To ensure the reliability, safety, and efficiency of these systems, various components must be carefully considered, with a focus on designing an optimal drone motor. This study aims to fill that void by proposing the development of a 3D-printed A2212 brushless direct current (BLDC) outrunner motor specifically designed for drone/unmanned aerial vehicle (UAV) applications. The A2212 BLDC motors were chosen for their low cost and availability, and the rotor was designed in SolidWorks before being manufactured using fused deposition modeling (FDM) with polylactic acid (PLA). The developed motor outperforms its conventional metallic counterpart in terms of performance. The 3D-printed polymer-based BLDC motor has a potential to revolutionize production by favoring polymer outrunners over traditional metal outrunners, promising reduced weight, extended flight times, and increased customizability. Maintaining a throttle at 50% for the initial 10 min and gradually increasing it to 70% over the next 10 min, the motor, even in static conditions, attained a maximum temperature of 40 °C. The study highlights experimental work in 3D-printed drone motors, emphasizing the potential for decreased weight, increased payload capacity, and longer battery life.