Expertise — Custom Actuators
Custom Actuators
Motor, drive electronics, transmission and sensors designed as one actuator, for the torque density and control quality catalogue parts cannot reach.
Discuss your project →Your machine needs more torque in less space, lower cogging, a shape no catalogue part has, or an actuator that survives heat, vibration or an explosive atmosphere. Combining off-the-shelf motors, gearboxes and drivers forces compromises on the whole system. We design the motor, transmission, sensors and electronics together, so the actuator is optimised as one.
What we do
- Electromagnetic design and FEA of BLDC, PMSM, stepper and voice-coil motors
- Frameless, slotless and high-pole-count motors for direct drive
- Transmissions such as gear trains, belt drives, ball and lead screws
- Compliant and series-elastic actuators
- Torque-density, cogging and torque-ripple optimisation
- Thermal design and cooling concepts
- Custom inverter hardware, including GaN and SiC power stages
- Field-oriented control (FOC) firmware, sensored and sensorless
- Encoder, torque and position sensor integration
- EMC-aware layout and filtering
- Functional-safety features such as Safe Torque Off
- Test-bench characterisation of torque, efficiency, backlash and thermal behaviour
Typical deliverables
- Actuator specification
- Electromagnetic, mechanical and thermal simulation reports
- CAD and manufacturing drawings
- Schematics, PCB layout and bill of materials
- Control firmware and tuning tools
- Prototype actuators with test reports
Frequently asked questions
Can you adapt existing components rather than design everything new?+
Yes. Often the fastest route combines a standard frameless motor kit or gearbox with a custom transmission or drive. We assess the options in the feasibility phase.
Do you design the drive electronics only, for a motor we already use?+
Yes. We develop drive hardware and FOC firmware for existing motors, including identification and tuning on our test bench.
Can the actuators be used in medical or ATEX products?+
Yes. We design with the relevant constraints from the start, for example insulation and leakage requirements under IEC 60601 or surface temperature limits for explosive atmospheres.
Have a mechatronic challenge?
Tell us about your project. We are happy to sign an NDA before any technical discussion.