World authority in design and manufacture

PMW is recognised as a world authority in the design and manufacture of compact high-power permanent magnet brushless DC electric motors. We offer many sizes of brushless permanent magnet and brushed pancake DC motors that can be rapidly tailored to meet your exact specification.

If you need a custom housing, very long life or just more performance than the markets standard offers, we can help. Printed Motor Works are able to assist with custom BLDC motors for volume production as well as low volume specialist projects. Typical custom projects range from a few weeks for simple adaptations to 16 weeks for a totally bespoke solution.

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Our Process
For Custom Electric Motors
01
Customer Specification of Motor
Deliverables

The customer delivers a specification of the required performance of the motor taking into account the motor torque and speed requirements over the relevant duty cycle.

PMW can assist with this phase and in some cases provide a strategic study to arrive at the best combination for the complete motion control system.

02
Magnetic and Thermal Motor Study
Lead Time

2-4 weeks from receipt of purchase order. Customer places order for magnetic study. PMW undertakes magnetic and thermal study.

Deliverables

Report with outputs from the magnetic study that will determine the electromagnetic configuration of the motor taking into account thermal constraints. Customer reviews the magnetic study report.

Cost

Depending on complexity.

03
Mechanical Design of Motor
Lead Time

2-8 weeks, depending on customer requirements. Customer confirms the specification of the interfaces between the motor and the rotary and static sides of the application, so that PMW can commence mechanical design.

Deliverables

Parasolid model of final motor (surfaces only) and outline drawings together with an updated firm quotation for engineering samples. Customer reviews the Parasolid model and outline drawings for confirmation of integration into application.

Cost

Charged per motor variant, depending on complexity.

04
Engineering Sample Motor Manufacture
Lead Time

2-8 weeks, depending on customer requirements. Customer confirms the specification of the interfaces and places order for mechanical design and samples.

Deliverables

PMW produces engineering samples in-house. Parts will usually be machined from solid, hand assembled and tested by our advanced production team.

Cost

Determined by the choice of motor size, electromagnetic configuration, mechanical design and quantities.

05
Volume Motor Manufacture
Deliverables

Finally, PMW can put together a complete plan for small or large volume manufacture involving tooling and set-up of a dedicated production line.

Challenges We Solve

Optimised Motor Performance

PMW offers a range of standard windings and stack lengths. But if these solutions don’t meet your needs we will work with you to develop a specification perfectly optimised for your application. PMW’s maximum slot fill manufacturing techniques and access to powerful grades of magnets means that we can optimise your motor to 94% efficiency at your load
point.

Customised stack length options mean that our BLDC motors can range from axially compact to very long axial lengths to adapt to clients needs. Our IR9 series has been designed down to only 35mm deep with 1Nm continuous performance.

Adapted Motor Housings

PMW helps our customers turn concepts into reality quickly. Using adaption’s of our existing housing designs we can produce a mechanical model to import into clients final assembly.

DC pancake motor with customised housing

Specialised Motor Configurations

For safely critical and applications with extended service life PMW BLDC motors can be configured for a wide range of demanding requirements. We have produced many motors for high temperature applications for example for fans on auxiliary power units that need to run in 150 Celsius plus continuous temperatures.

We have know-how of developing motors for off-shore use including full submersion using oil-fill techniques and pressure compensation.

PMW can also manufacture military specification motors with special suppression techniques to minimize electromagnetic interference.

DC pancake motor with customised housing

Full System Design

Due to our expert knowledge of motors and rotary systems PMW are able to offer value add services. PMW works closely with its clients to develop complete motion control systems. Projects have included development of a complete system for control and propulsion of a sports accessory, a revolutionary display system using motorised rotating light emitting diodes and a motorised warehouse robot.

As an example, for a rotating LED display system PMW provided a BLDC motor solution with the value added services of mechanical system design and validation, a 200W contactless power transfer, and PMW’s 500MB/s contactless data transfer technology.

Rotating LED display system using flat electric motor.

Production

PMW is able to deliver fully customised solutions on short lead times due to our expert knowledge and strong supply chain. Following a sample stage Printed Motor Works are then able to migrate the design to the volume manufacture stage using a combination of quality and low-cost suppliers to ensure your product has the right blend of quality and cost for its intended market.
Very large XR Series custom motor in build for large submersible winch system.
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