Custom Motor Designs and Manufacturing Support
Custom Motor Design
AOS RC supported an enterprise UAV company with the custom design, electromagnetic optimisation, and early-stage manufacturing of four distinct electric motor profiles. We acted as the technical bridge between the client and specialised production facilities to deliver tailored motors for the client's application.
Technical challenge
The client required unique torque profiles, thermal dissipation capabilities, and efficiency metrics that off-the-shelf commercial motors could not provide. To control unit costs while maintaining structural durability, the motors needed ground-up optimisation.
However, transitioning these designs into physical hardware created immediate manufacturing bottlenecks. The exceptionally tight tolerances required between the internal rotor and stator components exceeded the automated capabilities of the factory's standard assembly equipment, risking significant delays to the verification timeline.
Engineering approach
We used a structured engineering workflow to align computational design with physical factory capabilities.
Electromagnetic Optimisation: We customised existing motor baselines and designed new motor configurations. We mathematically modelled the internal electromagnetic components and air gap parameters to balance performance with production cost constraints.
Design for Manufacture (DFM): AOS RC managed the technical coordination between the client and the manufacturing engineers. We reviewed the factory drawings and adjusted component geometries to fit production capabilities. When equipment limitations prevented automated assembly for the initial validation batches, we collaborated with the factory to establish precise manual assembly protocols that preserved the required engineering tolerances.
Validation and Logistics: We finalised complete engineering design specifications ahead of schedule. To validate our simulation models against physical telemetry, we managed the ordering, quality tracking, and delivery logistics for low-volume production samples across four distinct sizing profiles.
Outcomes
Completed the technical design optimisation and manufacturing refinement cycles ahead of the original project milestone.
Successfully facilitated the production and delivery of 2,000 total sample units (500 units per motor model) to support client bench testing and flight evaluation.
Validated computational simulation models through factory quality control testing, proving the reliability of our predictive data.
Established a structured, repeatable production workflow that successfully transitioned the client to an established proprietary hardware line.