Custom BLDC Motor Design

I need a complete design package for a brushless DC motor—from first-principles sizing right through to manufacturable drawings. We will begin by confirming target torque, speed, efficiency, dimensions, and operating voltage together, then move into detailed electromagnetic and mechanical modelling.

Typical tasks will include:
• Electromagnetic optimisation in Motor-CAD, ANSYS Maxwell or equivalent
• Thermal analysis to verify continuous and peak ratings
• Mechanical CAD of stator, rotor, shaft, housing and cooling features
• Winding layout, slot-fill and material specification
• Loss, efficiency and torque–speed curve predictions
• Draft manufacturing drawings and a concise bill of materials

Acceptance criteria:
1. Simulation results that meet the agreed performance targets.
2. Native CAD and FEA files plus neutral formats (STEP, PDF).
3. A short report summarising methods, assumptions and final specifications.

Clear, well-commented models and files are essential so the design can move straight into prototyping or hand-off to a manufacturer.