02 — Actuator design

The actuator designed and optimised for your requirements and for the real life of your system.

We start from your constraints in terms of performance, footprint, cost and supply freedom and explore the design space using genetic algorithms: topologies, materials and dimensions compared systematically. The selected design is then validated by coupled multi-physics simulation: electromagnetics, thermal, electrical, control and vibrations. Control laws are estimated for a first prototype validation, reducing uncertainty before industrialization.

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This service is right for you if …

  • Off-the-shelf solutions do not meet your constraints: footprint, weight, thermal, severe environment.
  • You are developing a breakthrough product and need unprecedented performance from the machine itself.
  • You want to eliminate rare earths: to control your costs and secure your supply chain.
  • Your existing actuator is underperforming and you want to understand why: diagnosis and redesign.
  • You are in pre-series and need a validated design before committing to tooling.

Our approach

Pre-sizing Fast analytical exploration of multiple solutions in parallel to identify the best leads from the start, without heavy computation. Extraction of the best candidates for optimisation.
Optimisation Metaheuristic optimisation algorithms to systematically explore the design space and generate populations of optimal solutions. Analysis of these populations extracts the best designs.
Multi-physics simulation Validation by magnetic, thermal and mechanical finite elements with Flux2D/3D and FEMM. MATLAB/Simulink or Python coupling for system behaviour models.
Instrumented prototype Drawings, specialised sourcing and assembly. The prototype is instrumented to measure and validate performance under real conditions and define final specifications.
Industrialization file Finalised manufacturing drawings, experimental validation report, complete technical file. Preparation of the industrialization file and subcontracting package.

What you receive

A deliverable at each stage — from the first topology comparison to the file ready for series production. Every file is delivered in standard formats that your teams can take and evolve independently.

  • Comparative pre-sizing report — candidate topologies evaluated, rationale for retained choices.
  • Finite element simulation files — FEMM, Flux2D/3D, with magnetic, thermal and mechanical results.
  • Manufacturing drawings — complete drawings, tolerances, bill of materials.
  • Instrumented physical prototype — assembled and measured under representative conditions.
  • Experimental validation report — simulation vs measurement comparison, deviations analysed.
  • Industrialization technical file — ready for your subcontractors and industrial reviews.
FEMM Flux2D / Flux3D MATLAB / Simulink Python / in-house scripts BLDC/PMSM brushless motors Linear actuators Variable reluctance / SynchRel Magnetic couplers Genetic algorithms

Let us design your actuator together

Share your performance, footprint and cost constraints. We will propose an initial design direction.

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