Flux’s mechanical and electrical design teams shape innovation. Our everyday work most often revolves around our cutting-edge electromagnetic components and electrical designs, but behind every successful product lies the expertise of our mechanical design team, which ensures that each component fits seamlessly into existing applications. The collaboration between our Mechanical and Electrical Design Departments is a cornerstone of our innovation, and it's time to share how this synergy drives Flux forward.
Oliver Ekberg, one of Flux’s Electrical Design Engineers, plays a pivotal role in developing custom electromagnetic components. His designs are meticulously optimized to meet stringent customer requirements. “Electrical design is not just about achieving performance,” Oliver explains and further states;
“It’s also about working within the mechanical constraints of the customer’s application. Size, weight, and thermal management are just as critical as electrical performance.”
Oliver's typical day involves balancing electrical specifications with the realities of mechanical design. When faced with challenges like components that generate significant heat or need robust mounting solutions, collaboration with the mechanical team is essential.
Martin Thomsen, one of our mechanical designers, is one of the key figures Oliver turns to during the design process. Martin’s expertise lies in creating the physical structures that house and protect Flux's components. Whether it is designing spooling forms or crafting 3D models, his work ensures that each component functions optimally and endures the environments in which it operates.
“The process often starts when an electrical design reaches its limits,” Martin says. “If a component risks overheating or needs precise mounting, I step in to create the digital models and physical fixtures that make it work.” His ability to design stp. files and prototype tools are vital in transitioning designs from concept to production.
Lars Enna, Flux’s Facility Manager at the mechanical workshop, brings practical know-how to this process. Lars designs and fabricates custom tools to support the production of new products. From prototype spooling fixtures to specialized holding tools, his work ensures that designs are manufacturable at scale.
“A big part of my job is solving problems as they arise,” Lars shares and adds;
“Sometimes, the mechanical requirements change during production, and I have to invent tools that make the process smoother and more efficient.”
His proactive approach reflects the agile, hands-on environment within this step of the development process, where collaboration is constant.
The interplay between mechanical and electrical teams doesn’t stop at the initial design. Throughout the production phase, Martin and Lars provide feedback that helps refine designs for better performance and easier manufacturability. Whether adjusting fixtures or tweaking 3D-printed models, their input ensures Flux's products maintain the highest quality standards.
Oliver notes that one of the biggest challenges is aligning customer expectations with physical realities.
“Sometimes a customer’s request isn’t feasible as initially envisioned. That’s where our close collaboration really shines – we find ways to adapt and still deliver high-performing components.”
In Lars Enna's department, he expresses that these are some of the tasks that motivate him daily. Not everything is streamlined especially not in an industry as innovative as the space industry. He enjoys being part of converting obstacles into solutions.
While electromagnetic components may steal the limelight, it’s the mechanical design that ensures they perform reliably in the field. Lars emphasizes this point:
“My role is to develop mechanical components that help production create better products. Mechanics are often overlooked, but they’re essential to making sure our electrical designs succeed.”
Flux’s success lies in this harmonious blend of electrical innovation and mechanical craftsmanship. By working hand-in-hand, these teams not only overcome design challenges but push the boundaries of what’s possible in electromagnetic solutions. This holistic approach to product development is what keeps Flux at the forefront of the industry – ensuring that our customers receive solutions that perform flawlessly, inside and out.