Swift rewinds that save money
Armature Rewinds
The armature is the heart of a DC motor — the rotating component that houses the windings and works with the magnetic field to produce torque. When it fails, the motor fails with it. Our engineers carry out precision armature rewinding for DC motors of all sizes, using coils manufactured in-house, so there's no waiting on third-party suppliers and no compromise on quality.
Why choose Mawdsleys for armature rewinding
- We manufacture our own coils — no waiting on external suppliers, no delays
- A full team of engineers, not just salespeople — every enquiry is handled by people who understand the fault, not a call centre
- We’ve rebuilt motors others said were beyond repair — unusual designs, obsolete parts and complex faults are what we specialise in
- Full diagnostic before any work starts — once our inspection is complete, we give you a report and honest advice on the right next step
- ISO 9001:2015 accredited with full job traceability
Signs your armature needs rewinding
Catching a failing armature early can be the difference between a straightforward rewind and a full motor replacement. Watch for:
– Burning smell
– Sparking at the brushes
– Motor not reaching full speed
– Decreased power or torque
– Excessive vibration
– Carbon dust build-up
Common armature faults we see
Our engineers have completed hundreds of armature rewinds, and the same handful of problems account for most failures:
- Worn commutators — grooves or damage wear down carbon brushes quickly. Look for burn marks or an uneven commutator surface.
- Excessive vibration — usually caused by misalignment or damaged components, and left unchecked it accelerates overheating and further armature damage.
- Worn carbon brushes — a simple issue that escalates fast. Sparking, carbon dust and reduced motor power are the tell-tale signs.
- Burn-out — caused by overloading or poor airflow. If the armature has burned out, a rewind is essential — there’s no partial fix.
- Earthing/grounding faults — where the windings make contact with the metal core. This is a serious electrical fault and should be treated as urgent.
Our armature rewinding process
- Inspection & diagnosis — we assess the armature and identify the specific fault before quoting any work.
- Strip down — the armature is fully disassembled for inspection of the core, windings and commutator.
- Old winding removal — damaged windings are stripped back to the core.
- Coil manufacture — replacement coils are made in-house to the original specification, so there’s no delay waiting on suppliers.
- Rewinding — new coils are wound and fitted using industry-standard processes and materials.
- Commutator work — skimmed and undercut where needed to restore a true, even surface.
- Varnish impregnation — the rewound armature is immersed in insulating varnish for protection and durability.
- Testing — resistance, insulation and balance are tested before the armature is signed off and returned.
Case Studies
From 1935 to 2026: How 3D Printing Revived an “Unfixable” Heritage Asset
How 3D Printing Revived an “Unfixable” Heritage Asset
How Condition-Led Engineering Avoided £2m in Replacement Costs for UWE
We were approached by Collegiate School’s head of maintenance to fix a failed fan unit.
Zero Disruption At The Start Of Term
We were approached by Collegiate School’s head of maintenance to fix a failed fan unit.
Port Tender For The Repair Of 9 Electrical Motors
These types of motor repair tenders require fast and competitive quotes with an even faster turnaround.
Repairing an unusual Motor Generator set
The unit could not be replaced because of its unusual design and complexity.
Adjusting a replacement motor to our client’s needs
The client specifically required the new motor to achieve 4.4KW.
Armature Rewinds FAQ
What is a motor armature?
The armature is the rotating component of the motor that houses the windings and works with the magnetic field to produce torque.
What are the signs that the armature needs winding?
Signs which indicate that armature rewind is necessary include burning smell, sparking at the brushes, motor not reaching full speed, and decreased power.
How do I know if the armature needs rewinding or more in-depth repair?
We are DC motor armature specialists and we pride ourselves for giving you the whole picture. Once our inspection is complete we will provide you with a report and advice for further action. Get in touch today.
How much does armature rewinding cost?
Cost depends on the size of the armature, the extent of the damage, and whether the commutator also needs work. We inspect first and provide a fixed quote before starting.
How long does an armature rewind take?
Most rewinds are completed within days, not weeks — and because we manufacture our own coils in-house, we're not waiting on third-party lead times.
Can any armature be rewound?
In most cases, yes. Even armatures with unusual designs or obsolete parts that other repairers have turned away — this is one of the areas we specialise in.
What's the difference between a rewind and a repair?
A repair addresses a specific fault (e.g. bearing replacement). A rewind replaces the windings themselves, which is necessary when the coils are damaged, burned out, or shorting to earth.