3D Printed Electric Winch Strong Enough to Lift Me Straight Up

This is a mostly 3D printed electric winch that I build to pull myself up a climbing wall like a rope ascender.

I also made a video about the build and testing if you are interested. Here is the video: https://youtu.be/C--8uYFRu9c

3D Printer

Any Filament (non abrasive is better fort he gears)

Lots of printed parts, here is the printables link: https://www.printables.com/model/1366296-mostly-3d-printed-winch-strong-enough-to-lift-me-u

608 Bearings

30cm 6mm by 6mm steel square rod

4x 10cm 8mm diameter metal rod

2 Motor mounts, technically these can be 3D printed but I was afraid they would get soft so I used JLCCNC to get them machined out of aluminum.

2x 775 dc motor

Battery to power the motors

To control the motors you can use a three way switch or motor driver + Arduino combo

Various m3 screws

50 m5 15mm dome headed bolts

2x 5 mm motor couplings

4x 300mm 20mmx20mm aluminum extrusion, 6mm hole on 10mm and 90mm from both sides and both ends. 8 holes per piece

14x 115mm 20mmx20mm aluminum extrusions, the ends need to be tapped with m5 threads

2x 115mm 20mmx20mm aluminum extrusions, the ends need to be tapped with m5 threads and 6mm holes in the middles

1x 10mm 20mmx20mm aluminum extrusions, the ends need to be tapped with m5 threads

8x 360mm 20mmx20mm aluminum extrusions, 6mm hole on 70mm and 200mm

m5 Allen key

screw driver

I made video about this project and it includes more than I can do here like the necessary calculations,design decisions and the itself. Also wathing it would help out a lot.

We start with a lot of printing, the parts closer to the pulley are designed to be a lot more durable. With 3D printing we can help make those parts more durable by increasing infill and wall counts.

All the files are available in printables

Let’s start assembling. I begin by fastening the shaft holders to the 115mm profiles using T-nuts. Repeat this 4 times

Then I attach the 100mm handle to the two 115mm profiles with the holes in the middle.

Then I slide the other 115mm profiles

For the motor mount I didn't trust the pla filaments I had since they can melt so I used JLCCNC's services. They manufacture your your part for you from the material you want and send it to you with fair pricing. Lucky for me they also offer anodizing services which you can choose if you want o not when you order. I chose to have one part anodized blue and the other one red.

I attach the motors with two m4 screws and then I attach the motor couplings to the motor gears and put them on too the motors.

Get your first JLCCNC order at $1, click here to get the $70 coupon at JLCCNC: https://jlccnc.com/?from=can

Next I the shaft supporter to the two big gears

In order I attach on of the big gears and put the rod through it, then I put the pulleys, then the second gear and finally the end stops

I put the bearings in place and then put everything on like a shish kebab. Repeat for the other side.

I put the bearing holders in place, then assemble the kebab again and screw it in place.

I screw the motor in place(use Loctite) and the put heavy grease on slow gears and thin machine oil on the motor gears.

Now, time to test. I use myself as weight by of course taking the necessary safety precautions. I plan to take it to it's limits next time.