Inside the Lab: How Hekzatech Designs High-Thrust Motors for Heavy-Lift Drones

At Hekzatech, we specialize in designing custom BLDC motors that push the boundaries of performance. In this article, we’ll take you inside our engineering lab and show how we develop high-thrust motors for industrial and heavy-lift drone applications.

1. Requirements First: Every Gram Counts

Heavy-lift drones often carry payloads exceeding 10–60 kg. Our first step is always mission-specific analysis: thrust-to-weight ratio, thermal limits, efficiency targets, and mechanical stress under full load.

2. Stator Design & Winding Optimization

We use Ansys RMxprt and Maxwell for electromagnetic simulation. By adjusting slot-fill ratio, strand count, and winding layout, we achieve optimal torque density and minimize losses.

3. Rotor & Magnet Engineering

Rotor size, magnet arc percentage, and air gap tolerances are fine-tuned for maximum magnetic flux without saturation. We often use N52H or N45SH grade magnets for high-temperature endurance.

4. Thermal & Mechanical Durability Testing

Motors are tested under extreme heat and prolonged stress. We reinforce shaft-hub assemblies, use silicon steel laminations, and simulate dynamic loading to ensure long-term reliability.

5. ESC and Propeller Matching

We co-design high-power ESCs and test multiple propellers per motor size. PWM signal timing and BEMF feedback are calibrated for precise throttle control.

Designing high-thrust motors is more than increasing size—it’s about balancing power, efficiency, and durability. At Hekzatech, we engineer every component with purpose. Let’s build what others think is impossible.