Mahle's Magnet-Free EV Motor Exceeds 96% Efficiency

Mahle unveiled a traction motor that eliminates rare-earth permanent magnets by generating the excitation field with coils in the rotor, positioning it as a practical alternative for electric vehicles.
The design uses wireless inductive power transfer: an alternating field feeds energy to the rotor, where it is rectified into DC to energize rotor magnet coils that induce the air-gap field and produce torque, replacing fixed neodymium magnets.
Contact-free power delivery reduces mechanical wear and, combined with modern digital controls, boosts part durability and operational efficiency. Advanced electromagnetic simulation and control tuning enabled Mahle to optimize geometry and operating points, claiming efficiencies above 96%.
Removing rare-earth magnets reduces environmental impacts and supply-chain exposure - notably dependence on concentrated mining and geopolitical suppliers - while also promising lower overall cost for manufacturers. Mahle positions the motor as a scalable, high-efficiency option for next-generation EVs, potentially shifting industry adoption toward magnet-free traction drives.