Came offers a service to reduce industrialisation risks before committing to structural investments.
From theoretical design to concrete verification
The customer approached us at Came with a precise goal: to understand whether the project really had the right conditions to proceed to the next stage, without exposing itself to unnecessary risks. It was not about accelerating development, but stopping at the right time to verify the technical choices, constructional approach and real sustainability of the project from a production perspective.
The technical starting point was a compact BLDC with 6-pole stator, designed for applications in which every detail counts:
– small size,
– reliable insulation,
– long-term repeatability.
The customer contacted us with an active part already designed, but without any direct industrialisation experience. The request was clear: to have full support, capable of transforming a good technical project into something truly manufacturable.
An external studio had developed the electromagnetic design, while everything related to insulation and production integration was entrusted to us at Came.
The value of insulation co-design
With a customer that has no industrialisation experience, the biggest risk is discovering problems too late. So we at Came provided a co-design service, starting with the head and cap insulation as a key element to reduce uncertainties.
We designed the geometries with a single goal:
– avoid critical solutions,
– simplify the winding,
– make pre-assembly reliable.
It is not just about designing a component, but predicting what will happen when the project becomes real.
Prototype now to reduce the risk
To make the choices verifiable, we chose a very concrete approach. At Came, we made the insulation caps using 3D printing so that they could be validated quickly without incurring high costs. At the same time, we developed temporary tooling specifically for this initial phase.
This made it possible to pre-assemble the prototype and really assess the solutions adopted, before any final investment.
A prototype to confirm the choices
The project ended with a complete prototype, consistent with the initial goals. In addition to the wound and insulated stator, we at Came are able to support the customer with prototyping the synchronous reluctance rotor or permanent magnet synchronous rotor to verify the feasibility of the project in advance.
What really matters to the customer
From the customer’s perspective, the result is not just a working prototype. It is the ability to proceed with greater certainty, knowing that the choices made have been validated empirically. At Came, we work like this: fewer surprises after, more awareness before.
This is the most effective way to tackle complex BLDC projects without turning industrialisation into a leap of faith.
Fabrizio Bardelli
Came Research and Development Expert
consulting@came-italy.com
+39 0444 488282
