The Flange Coupler Flywheel Concept (FCW)
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Printed flywheel concept for brushed dart blasters.
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- Printables
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- Outdoor Sports
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- Creative Commons — Public Domain
WARNING: Printed flywheels can pose a significant safety hazard! The files I have posted are not meant to be printed! I posted them with the intention of a more experienced cad modeler/nerfer to remix the files into a printable product.
Behold! The flange coupler flywheel!
But what is it?
In short, the flange coupler wheel or FCW is a new concept of brushed flywheels. Its a step in the direction to be able to print high concavity flywheels for brushed motors in dart blasters.
How does it work?
Well, the reason why 3d printed flywheels and brushed motors don't mix is because brushed flywheels need to rely on a friction fit on a tiny 2mm shaft. Standard FDM printers just can't make a reliable friction fit that will last at 40,000+ rpm. Brushless flywheels don't have this issue since they can be bolted onto the motors directly. that is probably why we see a lot of printed brushless flywheels (think Hycon, the FDL projects etc.). By using a flanged shaft adaptor/coupler, we can screw a flywheel onto the coupler (like a brushless wheel is screwed on the motor) and then screw the coupler onto the motor's shaft. In theory, this should result in a better connection to the motor's shaft.
Printing Remixing one:
I wouldn't print these files. They are there purely for other more experienced people to have a go at the concept. I really don't know how it will hold up under the centrifugal forces or intense pressure or repeated impacts of launching darts. However, if you'd like to remix it you will find the f3d very helpful. Just find the sketch profile for the revolve and edit it to your hearts content.
Hardware needed (for one flywheel):
1x flange shaft adaptor (try and find an aluminum/titanium version).
4x m3x6 flat head screw (try and find a titanium/aluminum).
4x m3 nut (again, titanium or aluminum).
2 to 4 m2 grub screws. They usually come with the adaptor.
I would personally avoid steel as it would add unnecessary weight to an already heavy flywheel.
Final notes:
You might have seen these files up before. I accidentally deleted them and the back up :(. I am reposting the files again.
One more thing to note, the flanged shaft adaptor is a bit tall and might not fit in some blasters.
Change log:
18/10/26: spelling & grammer.