YASA develops axial flow motors without rare earths

Image: Mercedes-Benz (illustrative)

YASA has received funding from the UK government to develop a new generation of axial flux electric motors. The company is working on both motors that are completely free of rare earths and those that use fewer heavy rare earth elements. This work is part of Project Resilience.

Project Resilience focuses on two complementary technology pathways aimed at reducing dependence on rare earth magnet materials, while maintaining high power density, efficiency, and compact design. YASA aims to provide automakers with various motor architectures suitable for different applications.

Rare earth permanent magnets are used in high-performance electric motors, but their supply chains are highly geographically concentrated. This dependence exposes manufacturers and suppliers to geopolitical uncertainties, export restrictions, price fluctuations, and potential supply disruptions. Heavy rare earth elements are also used to ensure that permanent magnets can withstand high temperatures and harsh operating conditions, but they can be particularly difficult and carbon-intensive to extract and process.

For high-performance battery electric and hybrid vehicles, YASA is researching permanent magnet motors that do not use heavy rare earth elements. These are designed to achieve high power density without increasing the motor’s mass or size. Meanwhile, the company is developing entirely rare earth-free axial flux technology for applications with different requirements regarding performance, cost, and manufacturing.

Both development approaches are based on YASA’s common stator technology. This enables a modular motor architecture, allowing different rotor technologies to be used depending on the needs of a particular vehicle lineup. Tom Hillman, Head of Motor Simulation at YASA, said, “Different applications require different trade-offs in terms of performance, efficiency, size, cost, and production volume.”

YASA has been a 100% subsidiary of the Mercedes-Benz Group since 2021, employing over 300 people in Oxford, Bicester, and Welshpool. It develops and produces electric motors and power electronics for the premium automotive industry. The first Mercedes series model equipped with YASA’s axial flux motors is the high-performance electric car, the Mercedes-AMG GT 4-Door Coupé.

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About the author

Thomas Langenbucher is an expert in electromobility with experience in the automotive and financial industries. Since 2011, he has been covering electric cars, sustainable technologies, and mobility solutions for ecomento.de. Learn more.

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