Most manufacturing automation problems cannot be solved with off-the-shelf equipment. The product geometry, process sequence, quality requirements, and factory layout are specific to your operation. That is why Motionwell designs and builds custom automation machines — special purpose machines engineered for your exact application.
We handle the full cycle: concept development, 3D mechanical design, electrical and controls design, fabrication, assembly, testing, installation, and commissioning at your facility. Every machine we deliver is designed to be maintained by your team, with clear documentation, standard components where possible, and accessible service points.
Types of Custom Machines We Build
Rotary Indexing Assembly Machines
Multi-station rotary tables with servo-driven indexing for high-throughput assembly. Each station performs one operation — feeding, insertion, pressing, inspection, sorting — and the rotary table moves parts between stations with precise positioning.
Delivered examples:
- 12-station rotary assembly for medical safety syringes and blood collection tubes with vibratory feeding, vision inspection, and SCARA sorting
- 8-station rotary assembly for consumer electronics components with force-controlled insertion and inline testing
Automatic Test Equipment (ATE)
Enclosed testing machines with controlled environments, automated part handling, and data logging. We have delivered ATE for mechanical testing (insertion force, withdrawal force, bend fatigue), electrical testing, and functional verification.
Delivered examples:
- Cleanroom ATE series (P23018, P23046, P23049, P23050, P23063) with 4-6 FFU fan filter units for ISO Class 7/8 environments
- Multi-station circular transfer ATE with cobot auto-loading for connector and cable testing
- Pneumatic control test stations with real-time pressure and displacement monitoring
Precision Filling and Sealing Lines
Custom filling machines for pharmaceutical, food, and cosmetic products with volumetric or gravimetric dosing, heat or crimp sealing, and integrated inspection.
Delivered examples:
- Triple-head simultaneous filling and sealing machine for pharmaceutical oral liquids with ±1% accuracy and 20-60 units/min throughput
- Continuous dual-tray feed design allowing non-stop operation during tray changeover
- SUS304/316 stainless steel construction with food-grade and GMP-grade contact surfaces
Dispensing and Dosing Units
Precision dispensing systems with cartridge assemblies, servo-driven pumps, and level sensing for controlled liquid handling.
Delivered examples:
- Pharmaceutical dispensing units (P25026) with cartridge assembly and servo-driven volumetric dosing
- Multi-channel dispensing with recipe-based parameter control and automatic tare correction
Handling and Transfer Systems
Conveyor systems, gantry modules, and linear transfer units that connect stations and move parts through the process.
Delivered examples:
- Dual Z-axis gantry robot systems servicing 10+ CNC machines
- Chain conveyor and AGV transfer modules for warehouse intralogistics
- Servo-driven XYZ gantry modules for station loading and part positioning
Our Design and Build Process
- Process analysis and cycle time study
- Feasibility assessment and risk identification
- Concept layout with 3D arrangement drawings
- Component selection and lead time planning
- Budget estimate and project timeline
- Detailed 3D mechanical design (SolidWorks)
- Electrical schematic and panel layout
- PLC program structure and HMI screen design
- Safety system design per ISO 13849
- Design review with customer before fabrication
- In-house fabrication, machining, and assembly
- Electrical wiring, pneumatic plumbing, and PLC programming
- Internal testing with customer sample parts
- Factory Acceptance Test (FAT) at our facility
- Documentation package: manuals, schematics, part lists
- Delivery and installation at customer site
- Utilities connection and safety verification
- Site Acceptance Test (SAT) with production parts
- Operator training and maintenance handover
- Warranty support and spare parts supply
Design Principles
Every custom machine from Motionwell follows these principles:
Maintainability first. Your maintenance team will live with this machine for years. We use standard components (Festo, SMC pneumatics; Siemens, Mitsubishi PLC; Misumi, THK linear guides) so spare parts are available and your technicians can troubleshoot without calling us.
Clear fault diagnosis. HMI alarm codes map directly to causes and recovery actions. Operators should not need an engineering degree to restart after a jam.
Poka-yoke. Mistake-proofing at every operator interface. Parts can only load one way. Fixtures only engage when correct. Sensors verify before the process starts.
Designed for your operators. Ergonomic loading height, clear sightlines to the process, and intuitive HMI layout. The best machine is one that operators want to run.
Engineering Capabilities
- 3D design: SolidWorks mechanical design with FEA for critical structures
- Controls: Siemens S7-1200/1500, Mitsubishi FX/iQ-R, Beckhoff, Allen-Bradley PLC platforms
- HMI: Siemens TP/KTP, Weintek, Pro-face with recipe management and alarm handling
- Motion: Servo drives (Siemens, Mitsubishi, Beckhoff), stepper motors, VFD-driven axes
- Pneumatics: Festo, SMC with proportional valve control where precision is needed
- Safety: Pilz, SICK safety relays and light curtains, safety PLC modules, CE marking support
ISO 9001 Certified
Motionwell holds ISO 9001:2015 certification. Our quality management system covers the full project lifecycle from design input through commissioning and warranty support. Every project follows documented procedures for design review, change control, testing, and handover.
If you have a manufacturing process that needs a custom machine, describe your product, process, and throughput requirements. We will propose a practical concept within two weeks.