PEM announces research into Axial-Flux Motor without rare-earth magnets

In the NAFTech research project, scientists are developing an electric motor without magnets. Their proprietary design aims to combine the advantages of axial and radial flux technologies, producing an electric machine that eliminates the need for rare earth materials while remaining compact and efficient.

Naftech projekt e motor — Image: IEEE Xplore

The NAFTech project, which stands for ‘Sustainable Axial-Flux Machines Considering Tolerance-Affected Manufacturing Technologies’, brings together researchers from several leading institutions for this two-year initiative. Funded by the German government, the project involves the Production Engineering of E-Mobility Components (PEM) at RWTH Aachen, the Institute for Electrical Energy Conversion (iew) at the University of Stuttgart, and the Chair of Manufacturing Automation and Production Systems (FAPS) at FAU Erlangen. The primary goal of NAFTech is to develop an electric motor that contains no rare-earth elements while delivering high torque density, high efficiency, and a compact design.

Current axial-flux machines (AFM) already meet these criteria but almost always rely on rare-earth magnets, as noted by PEM in an accompanying statement. The project team aims to eliminate dependence on “those cost-intensive and increasingly scarce resources.” This has already been achieved by the radial-flux synchronous reluctance machine (RF-SynRM), which, however, according to PEM, “this entails compromises in terms of installation space and torque density.” NAFTech therefore focuses on the concept of an axial-flux synchronous reluctance machine (AF-SynRM), which is intended to combine the advantages of the two motor technologies.

“Axial flow machines are currently characterized by relatively low production volumes, manufacturing processes that are not yet fully developed, and special requirements in terms of tolerances and design processes,” explains Professor Achim Kampker, Head of PEM. The new project therefore adopts an integrated approach to topology, multi-domain machine design, and production methods, supported by data-driven optimisation of so-called tolerance chains. To validate the simulative design of the machine and the suitability of the manufacturing processes, specially constructed partial demonstrators will be used.

According to the project partners, the AF-SynRM promises economic advantages, particularly for small and medium-sized enterprises (SMEs), as it enables stable production costs and reduces dependence on volatile prices, such as those for rare-earth magnets. “A magnet-free motor reduces material costs by up to 50 percent, which can strengthen the competitiveness of SMEs and lower barriers to market entry,” emphasises Kampker. He also notes growing pressure to develop sustainable solutions to reduce CO₂ emissions and comply with regulatory requirements.

Early investments in magnet-free technologies can therefore provide SMEs with an innovation lead and open up opportunities in high-growth markets. NAFTech is intended to lay the foundation for this. The project began at the start of 2025 and will run until the end of 2027.

pem.rwth-aachen.de