Windings is 100% focused on providing custom electric motor solutions that are optimized, tested and manufactured to client-specific application requirements. Our engineering team is comprised of design and manufacturing engineers having extensive experience in engineering magnetic rotor assemblies, wound stators and complete motor assemblies used in civil and military aircraft, missiles, robots, medical equipment, oil well drilling, military vehicles and more. From performance and manufacturability optimization of existing designs to a complete engineering package from concept to production, Windings engineers have you covered. And unlike our competitors, Windings allows our clients to own any unique intellectual property developed by Windings for their application.

With more than 165 years of combined engineering experience and access to the latest design tools, Windings’ engineering team offers a host of professional engineering services to compliment and extend your internal capabilities. Services include application analysis and solution design feedback, part design analysis and simulation, prototype testing and reverse engineering of existing / legacy designs.

The electric motor engineering experts at Windings help our clients to:

  • Solve challenging or complex issues relating to critical applications
  • Achieve “stretch goals” for performance, reliability or cost
  • Compress tight new product development schedules
  • Supply rapid prototypes for proof-of-concept testing and design iteration

Frequently Asked Questions

What is the difference between ‘build to print’ and ‘design to specification’?
“Build to Print” defines when the customer supplies the manufacturer with a fully designed solution, including all drawings and specifications and relies on the manufacturer to build the product according to their specifications. “Design to Specification” defines situations where the customer supplies a set of requirements (physical dimensions, torque output, voltage and current, acceleration and velocity, etc.) and relies on the manufacturer to design (i.e. “engineer”) the solution.
How do I reduce losses in a motor?
The best way to reduce overall motor losses is to minimize winding resistance and stator core losses by specifying low core loss magnetic material for the stator laminations.
What are the benefits of Samarium Cobalt versus Neodimium Iron Boron?
Samarium Cobalt typically has higher absolute operating temperature than Neodimium Iron Boron.
What is highest achievable magnet wire slot fill?
Typically, anything above 80% slot fill is considered “high”. Designs intended for production on automated winding machines can achieve around 90% slot fill. With specific stator designs and highly trained / skilled workers using hand winding methods, 95% slot fill can be achieved. (In reality, 100% slot fill is not achievable.)

Technical Expertise

Motor Topologies:

  • Brushless DC motors
  • Permanent magnet DC motors
  • Wound field DC motors
  • Single and three phase induction motors
  • Synchronous motors and generators
  • Velocity and positioning sensors
  • Switched reluctance motors
  • Transverse flux machine
  • Manufacturing tooling and fixture design

Critical Performance:

  • Extreme Environments
    • -40°C to +260°C
    • Vacuum to 20,000 PSI pressure
    • Wet / wash down / salt spray
    • Cryogenic systems
  • Ultra-High Speed
    • 100,000+ RPM
  • High Power / Torque Density
  • High Vibration

Windings’ engineers are supported by engineering technicians and documentation specialists that are skilled both mechanically and electrically to provide packaging for our client designs, as well as technical documentation for our manufacturing team. With Windings’ 50-year history of manufacturing electric motors for critical applications, combined with our engineering team’s skills and experience, you can be assured that your project will transition smoothly and seamlessly from engineering and prototyping to pilot and full-rate production.