We worked closely with Nigel Atherton from Joulefusion to help him improve his product.

3D modelling of a new patented microgenerator, covering all aspects including a CNC milled housing with internal features to allow for magnet and bearing support, magnetic flux guides and electronic PCB. Additionally, an internal coil former was designed.

One challenge was to find a way of winding some small copper coils on to a former that would also accurately position the coils. The size and shape of the finished component meant that machining would be impossible. 3D printing could get us part of the way to a solution, however, for practical reasons, the coils needed to be wound flat and then be bent into a “U” shape.

We also produced a very high resolution 3D rendered image that was enlarged and printed on a 3 metre backdrop for an exhibition.