Prototyping plays a critical role in the design process and is fundamental to Windings’ commitment to concurrent manufacturing. Customers can work one-on-one with a Windings engineer during prototyping to review results and initiate changes. Custom prototyping can include anything from simple 3D printed components to test for fit between mating components, to a fully functioning motor assembly to test actual vs. predicted performance.

During prototyping, numerous design iterations can be quickly and easily tested to ensure the best possible outcome. Unfortunately, most companies don’t have the internal resources necessary to build and test prototype motors, and most motor manufacturers are not interested in low-volume custom jobs. At Windings’ prototyping (innovation, build, and test) is a core competency and is one of the reasons why we are a valued partner to our clients.

As the pressure to condense project schedules increases, so does the interest in rapid prototyping. Cutting days or even weeks out of a project schedule can have a tremendously positive impact on a project’s outcome. Winding’s willingness and ability to quickly build and test motors from scratch in low quantity can be a tremendous asset to our clients during the development phase of a project.

Typical client optimization goals include increased performance, manufacturability, and reliability as well as reduced manufacturing cost. Our rigorous stage-gate review process includes a technical evaluation for manufacturability, cost trade-off analysis, design iteration documentation, and management of solution implementation and innovation risk. In working with Windings, our clients have come to expect the achievement of optimized goals, streamlined prototype-to-production transition, condensation of overall project schedule, and reduced overall project costs.

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CUSTOM PROTOTYPING CAPABILITIES

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• 3D printing

• Test fit of mating components

• Simulate manufacturing steps

• Develop/refine production tooling

• Laser cutting of stator laminations

• Hand-winding of stator coils

• Custom machining and grinding of permanent magnet material

• Custom machining of rotors and other miscellaneous components

• Dynamometer test stands

• Speed-torque testing

• Thermal stress testing