Chris Handcock from EMS explores the subject
From bulky control cabinets that once dominated plant floors, to today’s compact drives embedded directly into process equipment, modern engineering increasingly demands greater capability with a reduced physical footprint.
But miniaturisation brings both opportunities and challenges in design. Here, Chris Handcock, design lead at drive system supplier Electro Mechanical Systems, explores how miniaturisation is changing product design.
For more than two decades, we’ve seen technology get smaller, and the same applies for the technology used in industrial spaces. This is evident in slimmer control cabinets, compact actuators integrated directly into equipment and smaller drive units embedded into packaging and finishing systems, often allowing original equipment manufacturers (OEMs) to reduce their machine footprint while maintaining access for maintenance upgrades.
Smaller, lighter, more efficient systems offer clear advantages, but miniaturising drive systems isn’t simply a matter of scaling down existing motor designs. It must carefully balance torque, power density, motor type and thermal management.
Miniaturisation in process environments
In manufacturing and process environments, miniaturisation is being driven by the need for higher throughput, cleaner layouts and more flexible production lines. Compact drive systems are now routinely used in applications such as conveyor positioning, valve and damper actuation, metering and dosing systems as well as automated inspection equipment.
By reducing the size of motors and gearboxes, machine builders can shorten axis lengths, reduce moving mass and place motion exactly where it is needed – often directly at the point of process.
In process industries such as food, beverage and pharmaceuticals, high-speed packaging and automated production lines are critical stages in the overall production process. Here, compact drive systems are enabling higher throughput and greater flexibility without increasing machine footprint. According to the Electric Micro-Motors Market Trends 2026 report, more than 55 per cent of newly designed production-line equipment upgrades now prioritise micro motor integration.
By reducing moving mass and eliminating complex mechanical transmissions, miniaturised drive systems support faster cycle times, improved positional accuracy and lower energy consumption, helping to maintain overall process efficiency in the same production envelope.
The challenge of compromise
But reducing size can create issues. Reducing motor size requires a careful balance of torque and efficiency to ensure performance doesn’t suffer. Small motors do not automatically deliver the same output as larger ones. To meet the same standards, engineers must carefully consider factors like torque output, power density, load-handling capability and energy efficiency. Smaller motors tend to have lower torque, meaning that designers may need to compensate with gearing, high-performance materials or alternative motor types.
Here, selecting the correct micro motor technology becomes critical. In process industry operations, Faulhaber brushless DC motors like those supplied by EMS, are often favoured for continuous operation owing to their efficiency, controllability and long service life.
Precision engineered through custom design
Thermal management is a critical bottleneck in miniaturisation. As motors get smaller, the surface area available for cooling diminishes. Left unmanaged, this heat accumulation degrades efficiency and damages components.
To address this challenge, designers must treat heat management as a core element of the engineering process rather than an add on. Approaches may include optimising magnetic materials, enhancing insulation, developing housings or airflow routes that improve heat dissipation, or integrating thermal sensors. In more advanced applications, compact systems may also feature heat spreading housings, micro cooling channels or other specialised thermal management technologies.
Addressing these considerations at the start of a concept is essential, as thermal limitations can dictate the performance envelope of a miniature motor. This is where precision manufacturing becomes crucial. Off-the-shelf motors and gear systems are often unable to meet the tight spatial, mechanical and performance constraints associated with tiny applications. For bespoke solutions, consider selecting a partner such as EMS, which provides a comprehensive custom design and manufacturing service, from its Dorset based facility.
By driving new expectations for system performance, energy efficiency and plant design, miniaturisation is reshaping the process industry. Compact, lightweight components are enabling tighter integration in both continuous and batch processes, unlocking capabilities that once seemed impossible. But real success demands more than shrinking hardware – it requires careful consideration of motor selection, uncompromised manufacturing precision and the support of custom design solutions that maintain process stability and uptime.
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