Solution
Custom Solenoid Design & Development
Cerebrus develops custom solenoids and electromagnetic actuators for OEMs whose products need a precise, compact source of motion or force that no standard component provides. We engineer the magnetic circuit, coil, and mechanics together so the device delivers the exact force-versus-stroke behavior, response time, and duty cycle your application requires.
Linear, rotary, and custom electromagnetic devices
We design linear solenoids that produce a straight pull or push, rotary solenoids that produce a defined angular stroke, and fully custom electromagnetic actuators for specialized motion. Because the device is engineered rather than selected from a catalog, the force curve, stroke, coil voltage, and envelope are all tuned to your product.
Solenoids are electromagnetic devices, and their performance depends on the magnetic circuit as much as the mechanics. We shape the pole geometry, air gaps, and coil design to achieve the force profile and efficiency you need within your size, thermal, and power budget.
From electromagnetic design to production
Development moves from electromagnetic and mechanical design, through prototyping and characterization, to a design suited for volume manufacture. We validate force, stroke, response, temperature rise, and duty cycle against your requirements, and account for the thermal and material factors that govern a solenoid's continuous-duty rating.
Because Cerebrus also builds embedded systems and machinery, custom solenoids are frequently developed as part of a larger device or machine, with the drive electronics and control designed alongside the actuator so the complete subsystem performs as intended.
Tools & methods
- Electromagnetic (magnetic circuit) design and analysis
- Coil design: turns, wire gauge, resistance, and thermal rise
- Force-versus-stroke characterization and tuning
- Mechanical design of plunger, pole, and housing in 3D CAD
- Prototyping and bench characterization
- Design for manufacturability and volume production
What you receive
- Electromagnetic and mechanical design
- Prototype solenoids for evaluation
- Characterization data (force, stroke, response, thermal)
- Drive requirements and, where needed, drive electronics
- Production-ready design and documentation
- Support for transition to volume manufacture
A typical engagement
A solenoid engagement starts from your force, stroke, response, and envelope requirements, moves through electromagnetic design and prototyping, and delivers a characterized, production-ready device — often as part of a larger product or machine that Cerebrus is also developing.
FAQ
Solenoids: frequently asked questions
What is the difference between a linear and a rotary solenoid?
A linear solenoid produces straight-line motion — a pull or push along its axis — while a rotary solenoid converts the magnetic force into a defined angular stroke. We choose or combine these based on the motion your product needs; fully custom electromagnetic actuators are also possible for specialized cases.
Why develop a custom solenoid instead of using a standard one?
A custom solenoid makes sense when you need a specific force-versus-stroke curve, response time, envelope, voltage, or duty cycle that standard parts do not provide — or when the solenoid must integrate tightly into a product's mechanics and electronics. Engineering the device to the requirement avoids the compromises of adapting a stock part.
How do you determine the force and stroke a solenoid can deliver?
Force and stroke are set by the magnetic circuit — pole geometry, air gaps, and coil design — together with the available power and thermal budget. We design and analyze that magnetic circuit, then characterize prototypes on the bench to confirm the force-versus-stroke behavior matches your requirement.
Can a solenoid run continuously, or only intermittently?
That depends on duty cycle and thermal design. Continuous operation raises coil temperature, so we design the coil and account for heat dissipation to achieve the duty rating you need — whether that is intermittent, high-force pulses or continuous holding.
Do you also provide the drive electronics for the solenoid?
We can. Because Cerebrus develops embedded systems and machinery in-house, we frequently design the solenoid's drive electronics and control alongside the device so the complete actuation subsystem is delivered as one engineered unit.
Have a project in mind?
Tell us what you're trying to build or automate. We'll help you scope it and recommend the right approach.