YouTuber shows 3D-printed tool for precise coil windings on small generators

A 3D printing model by Robert Murray-Smith, available free of charge on the Thingiverse platform, is intended to help with the precise production of fine coils for small generator projects. The model is aimed at users who, for example, carry out tiny wind turbines or similar experiments with electromagnetic induction and are dependent on precisely wound wire coils. The design is combined with standard components such as skate ball bearings and screws and can therefore be adapted to individual requirements.

According to YouTuber Robert Murray-Smith, the choice of wire diameter and number of turns for a project of this type is closely linked to the expected energy output. A thinner wire allows more turns in the same space and increases the output voltage, but decreases the current. Conversely, a thicker wire leads to higher current carrying capacity, but fewer turns and therefore lower voltage. The decision for wire thickness and number of turns is therefore based on an estimate of the expected performance level of the small turbine.

The coil winder produced with the 3D printer takes these requirements into account by making it easier to guide the thin wire. Especially with hair-thin wire, it is difficult to wind it precisely without a suitable device. The device makes it possible to apply uniformly thin wire in a high number of turns to a predetermined carrier structure. Users can thus produce coils that are precisely tailored to their magnetic conditions. This allows the voltage to be raised to the desired values without drastically affecting the already low performance.

According to the developers, assembly of the 3D-printed parts is comparatively simple. The system uses a hand crank to rotate the coil evenly, while the wire is held in position by a type of guide. Easy tension control, for example by applying light finger pressure or additional tensioning mechanisms, allows controlled winding without the wire breaking. Users can flexibly adapt the design, for example by selecting different diameters or different distances for a certain number of coil sections.