Tech Torqs #13: What Are the Key Aspects of Motor Design?
Designing a motor is never a linear process - it’s a constant balancing act between competing constraints. In this episode of Tech Torqs, we break down the key factors that define motor design and how engineers navigate trade-offs to achieve optimal performance.
April 28, 2026
Featuring John Kånstad, FiberPrinting™ Team Leader at Alva Industries.
The starting point is usually the envelope - the available space and mass. If there is flexibility, increasing the motor diameter is often beneficial, since torque scales with the square of the radius. Even small increases in size can significantly improve torque and efficiency.
Next come torque and speed requirements, which are closely tied to thermal limits. Adding more copper or stronger magnets can increase torque, but only if the generated heat can be removed. If not, thermal constraints will limit continuous performance.
This makes cooling a key factor in motor design. Improved thermal management allows higher current, enabling more torque or reducing weight for the same performance.
Finally, the operating environment plays a critical role. Factors such as dust, moisture, and vibration determine how robust the motor needs to be and influence material and design choices.
In the end, motor design is an iterative process, where multiple parameters are continuously adjusted to reach the best balance between performance, size, and reliability.
If you have a question about motors or motion systems, share it in the comments on our LinkedIn post or send it to us directly - we might feature it in the next Tech Torqs episode.
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