My First Homemade Brushed DC Motor
I finally built my first homemade brushed DC motor — and yes, it actually worked! But there was one big problem: sparks were flying everywhere, and the motor wasn’t spinning very fast. If you’re into DIY electronics like I am, you know that building your own motor from scratch is super exciting… but you also learn a lot through trial and error.
The Problem with the Aluminum Commutator
At first, I thought it was just part of the process. But after testing, I realized the main issue was the commutator. I used aluminum, which turned out to be a poor choice. It caused way too much sparking and didn’t conduct well under pressure. Lesson learned: copper is a much better material for commutators because it conducts electricity efficiently and holds up better over time.
Timing Is Everything: Commutator Positioning
Another thing I discovered — and this is something many beginners might overlook — was that my commutator wasn’t positioned correctly. It was switching too late. Ideally, it should switch current just 3 to 5 degrees after the coil leaves the magnetic field. That tiny timing adjustment can make a huge difference in motor performance. After repositioning it, the motor ran much smoother and faster, with fewer sparks and better efficiency.
My Motor Setup
- Insulated copper wire (0.6 mm) for two rotating coils, 40 turns each
- Thin copper wire brushes (0.5 mm)
- Aluminum commutator
- Power source: 12V, 1.6A
Click here to watch the video where I upgraded this motor and improved the performance.
Join Me on My DIY Motor Journey
This is just the beginning of my DIY motor journey. I’ll be posting more updates, including common mistakes, fixes, and creative experiments. If you’re into DIY electronics, motor building, and simple science projects, I’d love for you to join me.
Subscribe to my YouTube channel @MotorCraftLab and follow along!