Custom Encoder Designs

At Encoder Technology, we create and manufacture custom encoder designs for complex rotational applications and precision motion control. With over 50 years of experience in engineering, we support industries such as defence, aerospace, automation, robotics, and healthcare with tailored encoder solutions. 

Whether you require tailored precision encoder wheels, absolute feedback, or a full purpose-built solution for your project, our engineers work closely with you to develop the right encoder for your specific requirements.

Custom encoder designs play a vital role in industries where precision and reliability are critical. Our solutions are tailored to meet specific needs in rotational motion, linear measurement, and environments where standard encoders simply won’t suffice. These devices offer accurate feedback for position and speed control, ensuring flawless performance even in the most demanding conditions.

Typical applications include:

• Aerospace & Defence: Rugged, redundant encoders designed to endure vibration, temperature extremes, and electromagnetic interference.

• Automation & Robotics: Precision control for robotic arms, conveyor systems, and CNC machines.

• Medical & Healthcare Equipment: Customisable encoders for imaging and diagnostics where compact size and flawless accuracy are essential.

• Manufacturing Machinery: From draw wire units to high-speed lines, our encoders are built for tailored requirements and high performance.

Whether it’s a bespoke solution for mobile equipment, a bespoke encoder for robotic applications, or something as unique as a precision-engineered encoder wheel, we provide individualised solutions designed for a range of applications.

While standard encoder products offer fixed formats, special design encoders are engineered to suit unique application requirements – including purpose-built housing, connectors or cables, rotational diameters, and data formats.

Unlike optical encoders that may struggle in dusty or high-vibration settings, magnetic encoder solutions or custom-built optical designs provide accurate tracking and long-term resilience. We also design for redundant feedback, ideal for mission-critical roles in defence and aerospace.

Choosing Custom Means:

• No compromises on fit, function, or performance.
• Seamless integration with existing systems.
• The ability to scale from prototype to volume production.
• A customisable encoder matched to your application needs.

With over five decades of expertise, our team of encoder experts works in partnership with your business to deliver the bespoke encoder solutions you actually need – fast.

We Offer:

• Fully custom engineering from concept to completion.
• Fast turnaround and short lead times.
• UK-based service and support.
• High-precision components, including encoder discs, code wheels, and draw wire systems.
• Options for full customisation, including design features, output signal types, and bespoke encoder housing.

We’ve successfully delivered millions of configurations – including legacy replacements, one-offs, and high-volume manufacturing – across industrial applications worldwide.

Whether you need advice on special encoder designs, a replacement for an old encoder, or want to discuss your summary of encoder requirements, our friendly and professional team is here to help.

Contact us to start your project or speak to an expert about your specific application.

How long does it take to design and deliver a specially-made encoder?

Thanks to our rapid design process and short lead times, we can often deliver fully functional custom encoders in just a few weeks, depending on the complexity of your requirements. Speak to our team about your timeline, and we’ll work to meet it.

Can you help with replacing or upgrading an old encoder?

Absolutely. Whether you have an old encoder model with no direct replacement or you’re looking to enhance performance with a bespoke encoder design, we’ll match or improve on your existing solution using high-precision manufacturing and engineering expertise.

What types of customisations are possible?

We offer a variety of configurations, including modifications to rotational diameters, encoder wheels, draw wire capability, precision gear systems, output signals, and encoder housing. Whether you need redundant encoders, precision encoder wheels, or magnetic encoder solutions, we can build them.

Can you match specific data formats or protocols?

Yes. We can build encoders to support your individualised solutions with specific data formats, connector types, and signal outputs. Our team ensures compatibility with existing hardware, software, and motion control systems – no need for major redesigns.