DIY DC Generator (For Education Purposes)

Here is the plans for a DC generator that can be made from a small DC motor, cardboard, and a 3D printed pulley that will power an LED when turned. This is obviously not a feasible way to generate power, but it is a great way to teach kids about motors, electric generators, soldering, and other basic science and engineering concepts.

Materials:

• 5mm thick cardboard (roughly)
• Two DVDs
• Elastic Band
• Hot Glue
• Wooden Dowel
• Small DC motor
• LED
• Small length of Wire
• Access to a 3D printer and Laser Cutter

Instructions:

• Cut one of every part and 3 of the MidLayer
• Measure a length of dowel that is slightly longer than 5 widths thickness of the carboard you are using.
• Put a MidLayer piece on the end of the dowel and glue it in place.
• Put one DVD on next, followed by the CenterDisk, then another DVD.
• Put another MidLayer on top of that, then push the entire assembly through the Upright.
• Put another Midlayer on the dowel on the other side of the Upright, and glue it to the dowel
• Glue Upright into Base
• Glue SupportArm into Base and Upright
• Solder the wires and LED to the motor (You could add a 220 ohm resistor in series to prevent burning out the LED over time in my experience you wont be able to produce enough current to do that anyways)
• Install the pulley onto the motor shaft (can use a soldering iron or the bed of the 3D printer to heat up the pulley so it slides on the shaft easier
• Position and Glue the motor so the pulley lines up with the DVDs
• Run an elastic band between the pulley and the DVDs
• Glue a small section of Dowel to the side of the outside DVD to serve as a handle