The characterization of an electric machine can be evaluated using different available machine design and analysis softwares prior to manufacturing. These machine design softwares are either Finite Element Analysis (FEA) based or analytical model based. Each design software formulates and solves the machine design problem differently. Therefore, there is always a discrepancy in the results obtained from each of these softwares. The expertise of the user also affects the outcome of the analysis. Moreover, the desired performance of a machine is highly influenced by the manufacturing and assembly process of its various components. Hence, it is extremely important to characterize the design and performance of a special machine in different machine design softwares before and after fabrication. To validate the design methodologies, the accuracy of FEA softwares, machine models, as well as the manufacturing and assembly process, a comparative analysis should be performed between the results obtained from the software and experimental characterizations. 
In this thesis, the characterization of a variable-flux permanent magnet machine, synchronous reluctance machines (SynRMs), and a novel interior permanent magnet synchronous machine (PMSM) with improved torque utilization, is presented.  Three different machine design softwares, namely MotorSolve, MagNet, and MagneForce are used to characterize the machines. 
This thesis initially presents the characterization of a 7.5 hp variable-flux permanent magnet machine. The back emf, magnet flux linkage, torque-angle, and core loss characterization is carried out for this machine. An error band is introduced for the experimental torque-angle curves. This error band contains the tolerance and resolution of the torque transducer and conditioner. Additionally, an analytical model is implemented to estimate the core losses in the prototyped variable-flux PM machine.  The results obtained from software and experimental characterizations show an acceptable agreement. A comprehensive manufacturing and assembly process of the SynRMs for rapid prototyping is also presented in this thesis. The application of nonconventional photochemical machining process to produce the SynRM laminations is described. In addition, various stages of manufacturing, stator and rotor assembly techniques, rotor balancing procedure as well as specialized components used at various stages of the process are also presented. To validate the accuracy of the design and fabrication, the characterization of three SynRMs is then performed. This consists of static torque-angle characterization, inductance characterization, and dynamic characterization. An error band is also included for the experimental torque-angle curves. A regenerative dynamometer test system is developed to perform various static and dynamic characterizations. This test setup is equipped with a real-time supervisory controller as well as measurement and monitoring instruments.  
Finally, a novel interior PMSM topology with improved torque utilization to reduce magnet volume is characterized. The no-load back emf and static torque-angle are simulated and measured. A search coil based advance instrumentation system to monitor the machine’s parameters is discussed. The design, manufacturing, and implementation of the search coils to measure flux density in the stator of the novel interior PMSM are also discussed. 
For every characterization, a comparative analysis is performed to validate the design methodologies, accuracy of FEA softwares, machine models, manufacturing, and assembly process.