Researchers at the Department of Energy's Oak Ridge National Laboratory have introduced Motor Decide, a new analytical platform built to guide electric motor development. The tool helps automakers and suppliers evaluate alternative motor topologies based on critical material availability, cost, and supply chain vulnerability. By modeling trade-offs between rare-earth magnet dependency and alternative designs, the system aims to strengthen domestic EV powertrain manufacturing.
October 28, 2026·Charged EVs·Oak Ridge National Laboratory
Materials specialist Proterial and engineering firm FEV have successfully simulated a novel electric vehicle traction motor that functions without heavy rare earth elements. The concept combines amorphous alloy stator cores with heavy-rare-earth-free neodymium magnets to optimize efficiency and withstand high temperatures. The breakthrough aims to lower production costs and reduce automotive reliance on constrained rare earth mineral supply chains.
Indian EV powertrain startup Ferrstron Powertrains has begun on-road testing of a prototype 150 kW motor inside a 2.3-ton utility vehicle. The unit produces 400 Nm of torque and relies entirely on ferrite magnets rather than rare-earth elements. The company aims to offer a cost-effective, supply-chain-resilient drive unit for commercial and passenger electric vehicles.
Munich-based electric powertrain specialist DeepDrive has won a large-scale series production contract with an undisclosed global automaker, targeting a production launch in 2028. The deal will see DeepDrive supply its high-efficiency dual-rotor radial flux drive units for future electric vehicles. Alongside the manufacturing agreement, the supplier is establishing local operations in China to support international automaker partnerships.
Manufacturing engineering specialist Dürr has introduced the EcoMeter XS, a compact microdispensing unit designed to apply minute volumes of sealants and adhesives. The automated system aims to improve precision and efficiency across EV production lines, including battery cell assembly, pack sealing, and electric motor manufacturing.
UK-based Advanced Electric Machines (AEM) has unveiled the impressive performance specifications for its Titan motor, designed for heavy-duty electric vehicles. This innovative motor, part of AEM's HDRM range, distinguishes itself by achieving 700 kW peak power and 5,000 Nm of torque without relying on rare earth elements, addressing critical supply chain and environmental concerns in EV manufacturing.
Unlike traditional internal combustion engine cars, the vast majority of battery-electric vehicles operate with only one forward gear. This design choice is primarily due to the unique power delivery and wide, flat torque curve of electric motors, which eliminate the need for multiple gears to optimize performance and efficiency across varying speeds.
An EU-funded research initiative has successfully used 3D printing to create electric motor components from metallic glass. This innovative material, characterized by its disordered atomic structure, holds promise for improving the efficiency and performance of next-generation EV powertrains. The breakthrough could lead to lighter, more powerful, and potentially more cost-effective electric motors.
New details are emerging about the core technology powering Tesla's forthcoming Cybercab, revealing significant advancements in its propulsion system. The vehicle will incorporate a new 'Supermanifold V3' and, notably, utilize electric motors designed without rare earth magnets, a move with potential implications for battery material sourcing and sustainability.
Mercedes-Benz subsidiary YASA is developing new axial flux motor designs that aim to significantly reduce or eliminate the need for rare-earth metals. This initiative, backed by a UK government grant, could lead to more sustainable and cost-effective electric vehicle powertrains. The project focuses on creating high-performance motors less reliant on these critical materials, which are often subject to volatile supply chains.
Researchers at MIT have pioneered a 3D printing system capable of producing functional electric motors in a matter of hours. This innovative platform integrates multiple materials, drastically reducing production time and material costs, potentially revolutionizing hardware manufacturing by making it cheaper, faster, and less susceptible to supply chain issues. The technology aims to streamline the creation of complex electromechanical devices, moving beyond simple plastic prototypes to fully functional components.
