Improvement motivates: A word from our Senior Design Engineer

Our experienced engineers serve as the backbone of our business. They design, develop, and verify each customized component while ensuring they meet their intended purpose. There is much more to it than meets the eye. We spoke to one of our Senior Design Engineers to paint you a word picture illustrating the meticulous effort that goes into the job description of being an engineer at Flux. 

At Flux, we develop electromagnetic components for different industries, meaning we need specialized skillsets in-house. We have a dedicated line of staff across the entire organization that all contribute to the development and production of precision inductive components.

But how does it all come to life? We spoke to our Senior Design Engineer, Casper Hjort Wilson, to gain insight into the Department of Engineering for renewable energy, industry, and automotive. Casper has worked with us for 9 years now and is an integrated part of our workforce. With years of experience finding the optimal solutions, Casper is a trusted part of our team and a known face and voice to our customers. After graduating from the Technical University of Denmark with an engineering degree in Power Electronics, his skill set and passion for electronics led him to Flux, and we quickly realized what a great asset Casper would be to the company. 

Senior Design Engineer, Casper Hjort Wilson.

We meet customers where we are needed

In our line of business, we often communicate with fellow engineers as they possess the required skills to hand over the product specifications needed for the project at hand. Our experienced engineers are in charge of outlining the design and concept of ideas based on the product specifications received from the customer. 

Casper explains that they typically experience one of three approaches when initiating a new project with a customer. Not two projects are the same and must never be handled as such. This is why our engineers initiate each project with a specific approach intended to narrow down the challenge to a specified project description. 

Design verification and production

Customers bring a complete production drawing that merely needs to be produced by Flux.

Design Assistance

Customers need support in the design phase. Flux brings input and assists in the design process. 

From specification to production

Customers only bring product specifications and our engineers are given free rein to design the component and complete the development and production.  

A visualization of the 3 types of cooperation scenarios we typically experience from our customers. 

With these three types of cooperation scenarios, our engineers know how to approach the project. Regardless of the requested solution we consistently keep optimization in mind. This way, we can manufacture flawless products, made from the most beneficial materials and at the most effective conditions of production - a win-win for both parties. 

"In a process like this, we continuously keep an open dialogue with the customer to ensure that we are in complete alignment with the expectations and requirements while staying focused on product optimization throughout the process."

Casper Hjort Wilson, Senior Design Engineer, Flux

The process for a new project appears different in this line of industry than in, for instance, the space sector. Within the markets of renewable energy, industry, and automotive we work with high-volume deliveries meaning that the product specifications are usually different. Additionally, high-volume productions require more consideration of material choice as this can bring down costs significantly. We have the required knowledge to advise our customers on the best type of materials to use while still having longevity and quality in mind. 

An iterative process with constant dialogue

Our engineers supervise the manufacturing process of our electromagnetic components through design, development, prototyping, testing, and verification. Concurrently, they also work as the primary means of communication throughout the project. As illustrated below, our engineers are continuously in dialogue with the customer, reporting results and progress to ensure that we meet customer expectations. 

A visualization of the flow chart that our engineers review during a customer project.

The ongoing dialogue makes the process more iterative, which is a necessary step to achieve the superior performance we strive for. With continuous communication, we can detect potential errors or product features that do not align with the standards that the components are intended to have. 

In other words, these steps are essential for the product outcome. For instance, when working with components exposed to extreme environmental conditions, we have to create the best possible starting point making them as durable as possible.

A passion that grew fonder with time

Personally, Casper has always been very passionate about electronics. Already from a young age, he showed interest in the field and has cultivated a lifestyle ever since that makes room for his intensifying interest. Casper is not the only one who saw the field of power electronics as his calling - several of his co-workers took a similar path, having the same education from the same university. This creates a rewarding community amongst the engineers at Flux where the daily water cooler conversations can cover various topics, private as work-related. 

Flux Senior Design Engineer, Casper Hjort Wilson, at the annual power electronics exhibition, PCIM Europe in Nuremberg. 

There is no doubt that our Senior Design Engineer, Casper, enjoys the more nerdy parts of the job. However, he also has the hereditary gift of being outgoing and well-spoken when he engages with customers. For this reason, he has been an established part of the Flux representatives who travel to Nuremberg for the annual PCIM Europe Exhibition. Here, he makes conversation with interested visitors and current customers, passionately explaining the technical features of our electromagnetic components. 

"My daily drive is the ability to improve a product outcome. If I spot an opportunity to elevate a component, bringing it to the next level, I take it. It makes a noticeable difference to the customer and contributes to my personal learning curve. "

Casper Hjort Wilson, Senior Design Engineer, Flux

Our engineers all have their areas of expertise based on the markets they occupy. However, we always accommodate work pressure by lending engineers to departments where the resources are most needed. Casper is one of the engineers occasionally lent out to our space department, which has expanded his range of experience while gratifying his passion for improvement and personal development.  

What about the production? 

Click here to read about the lean manufacturing principles we have implemented at our Thailand facility where our electromagnetic components for industry, renewable energy, and automotive are manufactured. 

Superiority on a spectrum 

Our organization has approximately 6 dedicated engineers working within their respective markets. At Flux, we utilize the knowledge and experience sitting across from the table, meaning that we, through good old teamwork, cooperate to develop superior solutions for our customers. We have engineers who have been a faithful part of the organization for 30 years, newly arrived who just started their journey with us, and the ones in between. This way, we have established a versatile team of competencies that work closely together to achieve the best results. 

At Flux, we take pride in creating the best conditions for growth and personal development. It keeps up the daily motivation of our employees and ultimately creates a better workplace. We allocate time and resources for our engineers to participate in relevant courses that will help them stay up-to-date on the most recent innovations, technologies, and software programs. 

Do you wish to know more about our Department of Engineering in Asnaes, Denmark? Then reach out to John Willum, our COO of Industrial & eMobility, to find out more.