This project is a three-phase coreless PCB stator for a dual-rotor axial-flux permanent-magnet motor. The aim is to investigate whether conventional copper windings can be replaced by accurately manufactured PCB spiral coils to create a compact, repeatable and lightweight electric motor.

The stator consists of five identical 2-layer PCBs stacked together. Each PCB contains 12 spiral coils arranged for a 10-pole rotor and three-phase operation. The front copper layer contains the main spiral windings, while the back copper layer is used for the required interconnections between coils. The design uses heavy copper to increase the conductor cross-sectional area and improve the current-carrying capability of the PCB windings.

Two permanent-magnet rotor discs are positioned on opposite sides of the stationary PCB stack. When the three phases are sequentially energised by the motor controller, current flowing through the PCB coils produces a rotating electromagnetic field. This field interacts with the permanent magnets on the rotors, producing torque and rotating both rotor discs on a common shaft.

The project forms part of my final-year electrical engineering research and includes electromagnetic modelling, PCB winding design, motor control and the mechanical design of the complete axial-flux motor. Images included show the PCB winding layout and the development of the stator design.