Choosing the right motor for a prototype may seem like a straightforward decision that requires little consideration. However, most of the prototypes we analyze use oversized motors for their actual needs and functional requirements.
Below, we provide a guide based on the experience of Let’s Prototype to help you make better decisions when choosing motors for prototyping, regardless of your technical expertise.
Most prototyping teams fail because they start by selecting the component. The first step is not to choose the best-known motor; according to our methodology, motor selection should be the final decision.
To define these requirements, in addition to understanding the prototype’s overall objectives, we ask ourselves very specific questions, such as:
What Does the Motor Need to Move, and How Much Force Does It Need?
It is essential to quantify the motor’s required torque. At this stage, this objective value is determined through research and practical testing designed to simulate the worst-case conditions expected in the intended use scenario.
At What Speed?
After answering the previous question, we need to understand the speed requirements and limitations of the system. This information will be essential for determining the optimal motor sizing for the prototype.
What Type of Motion Is Required?
The answer to this question will help determine whether the motor needs to run continuously for long periods or, on the contrary, operate with frequent stops and starts. Properly characterizing the motor’s duty cycle will make it possible to determine the actual power required and estimate its potential service life—an essential consideration for the future product.
What Level of Precision and Motion Control Is Required?
This question may undoubtedly cause you to reconsider the conclusions you were already drawing about the best motors for your prototype. If the prototype simply needs to generate movement between two points, without requiring precise control over the motion cycle, the range of available options is extremely broad and affordable.
However, as additional requirements or constraints are introduced, the range of available options will narrow accordingly, and the solutions will become significantly more expensive. The requirements that most often lead us toward these types of solutions include the need to control precise positions, manage motion cycles, or achieve synchronization.
The most common mistake is trying to start with this step. The requirements defined above will significantly narrow down which type of motor is actually best suited for the prototype. However, since the question of what type of motor to use in a prototype is so common, we will take a closer look at the main pros and cons:
Even if you reach this stage with clearly defined motor options for prototype development, we must not lose sight of the fact that the motor is only a component, not the complete solution. Therefore, it is essential to understand the constraints of the prototype as a whole in order to determine its actual requirements.
These are some of the constraints that most often complicate the motor selection process:
Power Supply: An AC motor is not suitable if your prototype is battery-powered. Likewise, a 24V motor is not directly compatible with a system designed around a 5V power supply. The available power source is therefore a major constraint in the process of selecting motors for prototyping.
Form Factor and Size: In most cases, the product’s form factor and size are critical constraints. These variables are largely determined by market requirements. However, the ideal motor often does not fit within these physical limitations.
Operating Environment: Every prototype has a specific operating environment based on its functional objectives. Exposure to dust, moisture, vibration, or other particular conditions may also influence whether certain motor options are selected or ruled out.
Balance Between Technical and Economic Feasibility: This is a key consideration in any prototype. Throughout the prototype development process, it is important to remember that behind every prototype there is a potential business. Therefore, keeping a close eye on the cost of the motors used to achieve technical feasibility is not only important—it can be decisive for the product’s future viability.
Having more than 10 years of experience designing and manufacturing prototypes brings both advantages and challenges when it comes to selecting the right motor for each prototype. Over that time, and across more than 500 prototypes, we have gained extensive experience and worked with virtually every available motor solution. However, that same experience can sometimes create the temptation to rely too heavily on intuition rather than rigorously following each step of the selection process.
At Let’s Prototype, we have learned that selecting the right motors—like every decision that can affect the balance between a prototype’s technical and economic feasibility—requires a solid initial planning process. This allows us to address the key questions that introduce uncertainty into the prototyping process.
The time to bring your ideas to life is now. We accompany you throughout the entire process: from idea to product.
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