The best way I think to build this device is by using Lexan and sandwich the coils and the magnets with 2 pieces each to make the unit serviceable.

@KyleCarrington Of course, Hugh has used an iron axle, bearing, because his units are VERY large and require huge strength. But, as you've pointed out, his stators have no iron, only coils, resin, and wood. Less cogging. We're making current, not electromagnets LOL

@KyleCarrington yeah the voltage will always cross past zero because the magnets alternate between north and south (up/down) but I don't know the finer points of motor design to say exactly what design is best. I think it's a decent design but it's quite possible it could be better. I'm still learning about magnetism. it's surprisingly complex

i like your idea a lot but a real challenge with future concern, is to have a unit not using copper at all, since we are running out that precious metal.

yeah layered gives a good power density and nice symmetry.

it's not a free energy device. you can use it as either a motor or a generator. if you power it electrically it's a motor, if you use something else to spin the magnet disc then it's a generator

@spotlightman1234 I know there is iron in the magnets. by ironless is meant no iron in the stator that the magnets can 'stick' to. the idea is for the motor to be able to freewheel spin with minimal loss unlike most motors

@ihjmobile : ) it's 3d studio max with mental ray renderer although the vray renderer is nicer to use and often produces better results

@KyleCarrington People confuse a car alternator with a permanent magnet alternator, a car alternator requires the iron, because they have no magnets! Electricity energizes the coils, with their cores as to have a magnet... at all...

@DanFrederiksen 'Blender' works well!, but it is also counter intuitive. The real advantage is... it's FREE.

A ferrite core will exponentially increase the flux density. Are these for high speed low torque applications?

@HHH100 what? first of all it's intended as a motor, you know for electric cars. but it could also work as a generator on for instance a wind turbine or as a range extender with a combustion engine. I'm not talking about a free energy device here. I think you got confused.

Dan, if your magnet are so big, in comparison to the hole, (center part of each coil) can the voltage ever reach zero, as to create a magnetic field/effect, in the first place? I thought they'd have to be slightly smaller than the hole.. itself. If I'm making any sense lol

one problem with your iron free design neodymium magnets are an alloy of neodymium, boron, and IRON but i do get the whole point you could use cobalt samarium magnets those have no iron

put 2 disks on either side of the wires which are should spin if placed and apply force maybe needed 4 larger affect

@FreeMagneticEnergy2 it's not an engineering program. just 3d. it's max and the renderer is mental ray. I tried mental ray because it's quite fast but I don't like how it works. you have to tweak materials and lighting and exposure a lot for it to be reasonable. a lot of things done wrong in that design. good thing I'm making my own renderer. show em how it's done : )

@MrTpengineer I was thinking fiber composite. at high rpm it will need strength that plastic doesn't have.

@TrueNevose it was designed to be more efficient because there is no cogging and iron losses. and your premise that it would have been done before if it was good is equally flawed