As a forward-thinking company, Magnomatics has a role to play in nurturing and inspiring the next generation of industry talent. An important part of that role is offering placements to undergraduate students. Over the last year, we have been pleased to have two University of Sheffield aerospace engineering students, Tom Findlay and Lawrence Needham, working with us.
Tom, who has always wanted to work in STEM and is interested in anything science-based, intends to study for his Master of Science degree after graduating. He found his placement through university partnerships and chose Magnomatics to further his understanding of the aerospace sector, where he is considering a career.
Lawrence, who will also go on to study for his MSc, is interested in Formula 1, aerospace and automotive engineering. He too found his placement through university connections but chose Magnomatics for the opportunities to gain design and build experience, learn about the full manufacturing process and gain insights across the business.
As their placement came to an end, we sat down with Tom and Lawrence to ask them about their time at Magnomatics.
What interested you in completing your placement at Magnomatics?
Tom: While Magnomatics works in aerospace, my degree subject, I chose to come here because they also work with other interesting sectors. This has helped me widen my scope and experience, particularly in renewables, which will be vital in my future career.
Lawrence: As I enjoy the design, engineering and mechanical side of things, Magnomatics was a great choice for getting hands-on experience in exciting R&D projects. Trusted from week one and thrown straight into projects, I’ve been able to get involved in multiple facets of the internal process.
Can you tell us a little about the projects you worked on during your time with the team?
Tom: We worked on everything from sub-sea ROV tooling and 3D printing, to automated magnetic Gauss testing and procedure, to automated magnetic Gauss testing and procedure. We also got stuck into the High Temp Actuator Project, which involved potting trials to encapsulate wires, preparing samples for testing using 3D print tooling, and R&D trials to down-select the best potting compound for 400 °C performance – something never done in the industry before.
Lawrence: The precision coil winding machine was a fascinating project as it required the full design, building and testing of a machine with high-precision, compact, segmented motor windings. We used a modular design to allow for easy changes, as we were testing the winding of two prototype stators. We tested multiple areas before the build to ensure success and did simulations of the forces experienced by the machine to ensure safety and reliability. It was a big project too, with a 24m rig and a series of pulleys with a 6:1 ratio to keep the wire tensioned over a long distance.
Tom: As aerospace students considering careers in the aerospace industry, we both relished the opportunity to work on the UAV design project. This was to design the end formers for winding a high-packing factor stator in an ultra-efficient UAV. This involved running simulations on the casing and finding ways to reduce mass while maintaining strength – something that required a full re-design of the front casing endplate.
Lawrence: The UAV project required a lot of research, including the performance of adhesives at -70 °C. This involved finding companies that could perform the tests to our specifications as adhesive temperatures aren’t usually tested below -40 °C. We also had to research and make a decision about the high dielectric strength epoxy powder coating that would be used on the stator.
How has the experience been? Were you supported by the Magnomatics team?
Tom: I didn’t expect to be given the level of trust and breadth of project involvement that we did. I’ve widened my scope beyond expectations and now have a clear understanding of what a day in the life of Magnomatics looks like. In terms of support, it was a very welcoming environment. Our undergrad questions were always answered, we were given genuine responsibilities, and we were encouraged to work independently. Overall, it was a very valuable experience, and I learnt a great deal.
Lawrence: To be trusted to design and build the precision coil winding machine underscores the value that the placement had for me. Being responsible for everything from design to testing and being told that there is serious potential for Magnomatics to use this device across all future builds, has given me industry experience I could not have got on campus. However, this would not have been possible without the exceptional experience and support of the senior Magnomatics team.
As someone who loves problem-solving, I also really enjoyed the High Temp Actuator project, which required a lot of trial and error. Overall, the placement has been very educational and has strengthened my interest in the aerospace sector.
What are your hopes for the future?
Tom: While the next step is to take my MSc in aerospace engineering, my time at Magnomatics has given me a much clearer picture of how the industry works, its challenges and opportunities, and the range of exciting R&D taking place. It’s certainly fired my enthusiasm for a future in the industry.
Lawrence: I've got a much deeper understanding of the processes that take place in the industry and a greater awareness of the opportunities that are available to me once I finish my MSc. What I particularly liked about Magnomatics was the diversity of projects taking place and this will be influential in my future career decisions.
Magnomatics would like to thank Tom and Lawrence for their hard work and dedication during their placement and we wish them all the best for their future studies and careers.
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