Hand-built monster fan

Hand-built monster fan on 6 × 32140 cells: original 3D-printed structure joined with heat-set inserts, 3660KV brushless motor + aluminium blades bursting to 1200W; insulating rings on the cells, AWithZ U3 on manual weld, about 100A by Ohm’s law and a single nickel layer only passes 33A, so three layers stacked in a row; over 1000g of thrust

A monster fan hand-built on 6 × 32140 cells. The 3D-printed model is his own design, prints well, and the whole structure is joined with heat-set inserts. The motor is a 3660KV brushless paired with aluminium blades; the small motor can burst to 1200W. Insulating rings go on the cells, then spot welding with the AWithZ U3 welder set to manual; the motor is rated 1200W, which by Ohm’s law is about 100A, and this nickel strip passes at most 33A, so three layers of nickel are stacked one after another to make sure the cells can deliver their full discharge rate; the welds come out perfectly smooth. Cells in, fan housing and grip screwed together, done; thrust tested at over 1000 grams. Comments: asking for the files (×2), no mould needed?, how much did it cost, ‘1200W? my e-bike is only 1200W’.

Outcome

Steps4 steps · click a frame to jump

1. 
   1. 6 × 32140; original 3D-printed structure, heat-set inserts

   A monster fan hand-built on 6 × 32140 cells; the 3D print is his own design and came out well; heat-set inserts join the structure.

   00:00 – 00:10
2. 
   2. 3660KV brushless motor + aluminium blades, 1200W

   A 3660KV brushless motor paired with aluminium blades; the small motor can burst to 1200W.

   00:10 – 00:18
3. 
   3. Insulating rings; U3 on manual; 100A → three layers of nickel stacked

   Insulating rings on the cells; AWithZ U3 on manual weld; 1200W rated is about 100A by Ohm’s law; the nickel strip passes at most 33A, so three layers are stacked in a row to get the full discharge rate.

   00:18 – 00:38
4. 
   4. Perfect welds; housing and grip on; 1000g+ thrust

   The welds are perfectly smooth; cells in; housing and grip screwed together; thrust tested at over 1000 grams.

   00:39 – 00:51

Bill of materials

Measured on camera

Creator’s tips

• Estimate current from power; a single nickel layer is limited to 33A, so stack several layers for high current 00:27
• Heat-set inserts make 3D-printed parts join more securely 00:08

Li-ion safety

• ~100A discharge — the connections must carry it 00:27

Quotes