Innovations in Electromagnetic Design for Aerospace

Aerospace components must deliver lightweight strength, verified reliability, and high efficiency—often under the most demanding conditions imaginable. That’s why the latest advances in electric motors, generators, stators, and rotors have such a meaningful impact.

Better electromagnetic design means more input power is converted into useful work—with less heat, less noise, and fewer losses. The result? Aircraft systems that extend range, increase payload, and improve mission endurance—without compromising safety or serviceability.

Where Innovation Shows Up

Today’s high-performance electric motors achieve greater power density using:

• Tighter air gaps
• Refined laminations
• Optimized magnetic geometry

Advanced windings improve slot fill and minimize copper losses. Insulation systems now protect performance across extreme temperature and pressure cycles. And when paired with efficient electronics and cooling systems, these design choices lead to measurable system-wide gains.

Design Advances Raising Performance

• Efficiency first: Geometry, materials, and winding strategies are chosen to reduce core and copper losses throughout the duty cycle.
• Thermal margin: Resins, varnishes, and engineered heat paths preserve performance across climb, cruise, and dwell phases.
• Weight reduction: Precision-engineered components trim mass while maintaining structural integrity and service access.
• EMI control: Shielded layouts reduce electromagnetic interference with sensors, radios, and avionics systems.
• Maintainability: Repeatable builds and clean documentation simplify inspection and overhaul procedures.

Reliability You Can Prove

In aerospace, predicted performance must match real-world results.

At Windings, we build aerospace components with production intent from the start. That means the same materials, standards, and quality checks are used in prototypes as in final builds. Traceable materials, traveler documentation, and inspection records make audits and certifications straightforward.

When a stator, rotor, or electric motor meets performance targets in test, programs gain confidence that carries through into flight.

From Prototype to Production

Rapid prototyping bridges the gap between concept and flight-ready hardware. By using the same materials and standards intended for production, late-stage surprises are minimized and pilot runs become smoother.

Structured engineering reviews identify issues early. Pilot builds validate yields, work instructions, and maintenance documentation—de-risking scale-up and certification phases.

Why Teams Choose Windings

Windings engineers and manufactures precision electromagnetic components for mission-critical aerospace programs. Our team collaborates on:

• Specs and stack-ups
• Magnetic architecture
• Manufacturability and quality alignment

With in-house prototyping, clean build environments, and disciplined process control, we ensure repeatable performance and predictable schedules. Simply put, the parts behave as modeled—and scale without drama.

A Practical Next Step

Small performance gains at the motor or generator level can compound across an aircraft’s entire lifecycle—impacting range, electrical load, and service costs.

If you’re launching a new platform or upgrading an existing one, begin with the components that convert energy. Align the design to your system envelope, validate with discipline, and carry that confidence into production.

Key Applications Across Aerospace

• Propulsion and actuation for eVTOLs, UAVs, and hybrid aircraft
• Power generation in auxiliary power units and ram air turbines
• Precision motion control for gimbals, payloads, and flight surfaces
• Space-ready systems with vacuum and thermal resilience
• Quiet, efficient subsystems that reduce cabin noise and power load

If your team is defining next steps for a new aircraft system—or refreshing a legacy platform—Windings can help translate technical requirements into aerospace components that scale with confidence.

Explore our tailored engineering approach, or connect with us when you’re ready to review manufacturability or plan a pilot run.