Custom Motor Controller and Inverter Design | UK
UK-designed and manufactured motor controllers, built to your exact spec — from single prototypes to volume production.
Zikodrive designs and manufactures custom motor controllers for brushless DC, stepper and asynchronous motors, for OEMs who need something a stock drive can't deliver — whether that's a tighter form factor, a specific interface, a cost target, or a compliance requirement. As a high-mix, low-volume specialist, we take projects from initial spec through to ISO 9001-certified production, all under one roof in West Yorkshire.
Why Custom Design a Motor Controller?
The Technical Case
A custom motor control solution is worth considering when stock drives don't fit — whether that's a form factor constraint, a performance requirement outside standard ranges, a specific communication interface, or a compliance need a generic product can't meet.
Production Savings
Custom development involves an upfront design cost, but it typically pays back through production. Off-the-shelf controllers are built for a broad range of applications, so you often pay for capability you don't need. A custom design includes only what your application requires — which usually means a lower unit cost at volume, not just a better technical fit.
Motor Types and Expertise
We design controllers for stepper, brushless DC and asynchronous motors — matched to your performance, interface and compliance requirements.
Stepper
- Open loop or closed loop control
- Frame sizes up to NEMA 42
- Integrated into motor frame, existing product casings or panel mount.
- Can be supplied with fixed settings or optional parameters depending on requirement.
- Piggyback options for integration into other control boards.
- Microstep resolution up to 1/256.
BLDC / PMSM / IPM
- Sensored or sensorless
- Integrated (motor-mounted) or standalone
- Typically operate up to 50A / 48V max.
- FOC / Trapezoidal / MTPA / SVM options depending on requirements.
- Field weakening options.
- Range of interfaces.
- Standard or enhanced fault management methods.
- Range of interfaces.
Asynchronous
- High frequency, high efficiency options
- Full tuning capability to enable operation with range of motors.
- Optional dual asynchronous and BLDC controllers if flexibility needed.
- Speeds up to 100KRPM and higher.
- Typically operate up to 50A / 48V max.
Typical Timeline
Initial consultation / headline specification
A quick chat with the team to discuss your project and understand the key requirements.
Detailed Specification
Once we're clear on what's needed, we prepare a detailed specification.
Proposal and Quote
We'll prepare a detailed quote including NRE and production pricing.
Project Initiation and Start
Project starts, we'll keep you informed as it develops with a clear communication plan.
Prototype Validation
Once the prototypes are designed and built, we'll run acceptance testing, supplying you with a small batch and test report.
Prototype Debugging
Where necessary, we will conduct minor debugging / finalisation work to ensure prototypes meet your needs.
Production Readiness
Once prototypes approved we will get setup for production volumes, adding everything to ERP and ensuring all EOL test requirements setup ready for first production orders.
Compliance
We have direct experience across safety, EMC, environmental and materials compliance — including the standards below. Where a project needs testing we haven't listed here, we can scope that with you at the spec stage.
DIN EN 61800-5-1 — Safety requirements for adjustable speed electrical power drive systems
IEC 60601-1 — Safety requirements for medical electrical equipment
UL Registration — US safety certification/listing
IEC 60601-1-2 — EMC requirements for medical electrical equipment
IEC 60068-2 — Environmental testing (temperature, humidity, vibration, shock)
IEC 60529 — Ingress protection (IP) ratings against dust and moisture
ROHS / REACH — Restriction of hazardous substances and chemical safety compliance
UL94 — Flammability rating of plastic materials
