Electric motor exploded view.
Aerospace electric motor design.

Electric Motor Reverse Engineering

WHen preservation is sensible

  • No OEM Support = Reverse Engineer

  • Poor OEM Performance = Reverse Engineer

  • Sole Source Supplier = Reverse Engineer

If your current program has a qualified solution but is suffering from a lack of support from the OEM, your program is recieving poor performance from a current supplier, or if your program must mitigate the risk of a sole-source supplier, it may be time to explore new procurement avenues. However, for most ongoing programs, designing, qualifying and implementing a new electric motor or generator can be cost prohibitive. Often times a company will opt to reverse engineer their current solution in order to support ongoing programs. Where feasible, this approach can prove beneficial for programs with cost and schedule sensitivities.

If your ongoing project has an electric motor that requires continued production, but you are facing an obstacle to getting the support your project requires, let Axon’s team recreate and fabricate the motor to help mitigate project risk. Whether the motor is an AC induction motor or a brush DC motor, Axon can help. With a sample unit to measure, test, analyze and tear down, Axon can recreate the unit. Axon’s team can fabricate the device for your team, or Axon can sell the entire drawing package outright, allowing you to source and fabricate the units anywhere you’d like.

Form, Fit and Function Vs. Replication

Reverse engineering and fabricating an existing design can range in difficulty from recreating the form, fit and function of the unit, to total replication of the original unit to the greatest extent possible. The former allows the Axon team to use the latest best practices in design, materials and finishes, whereas the latter will try to replicate every material and finish, regardless of recent industry improvements. Based on your specific program requirements, your team will decide to what level of replication is required. However, since the inception of the original design, many new and improved materials and epoxies have likely become available and should be utilized where possible to improve the quality and robustness of the design. These newer materials and epoxies typically have improved insulation materials, increased temperature ratings, greater adhesion, increased strength, or the removal of dangerous chemicals like hexavalent chromium.


In addition to deciding the level of replication required, the program may require additional performance testing or even limited qualification testing. Axon’s team can help construct and execute a test plan to meet your program’s needs. Axon has the ability to perform extensive in-house testing and can work with qualification testing laboratories located in Florida (or we can work with any national laboratory your company may prefer) to perform extensive environmental and electromagnetic effects testing.