There is a silent revolution taking place under the bonnets of today’s most sophisticated electric cars. While the majority of the hype surrounding EVs surrounds range, charging time, or sexy appearance, the actual game-changer could be in the motor itself. Car manufacturers and suppliers are redesigning one of the most important parts of an EV—and it all begins with rare-earth magnets.
Why Rare-Earth Magnets Are Falling Out of Favor
For decades, rare-earth permanent magnets have been the backbone of electric vehicle drives. They assist with providing the type of power and compactness necessary to rival—and more often than not, surpass—gas-powered engines. But at a cost. Materials such as neodymium and dysprosium are expensive, environmentally toxic to produce, and predominantly supplied by a handful of nations. That introduces supply-chain headaches, sustainability issues, and geopolitical risks that most automakers are keen to escape.
The Advantages and Disadvantages of Permanent-Magnet Motors
Approximately 90% of modern EVs use permanent-magnet synchronous motors (PMSMs). They are efficient, strong, and small—but flawless. Since they use rare-earth components, they are sensitive to supply chain disruptions. They also induce magnetic drag on coasting, which wastes energy, and are susceptible to overheating, which can cause permanent demagnetization.
The Revival of Wound-Rotor Motors—With a Twist
One possibility is the wound-rotor synchronous motor (WRSM). Rather than permanent magnets, these motors create a magnetic field with electromagnets—namely, loops of wire energized by electricity. The design isn’t new, but it’s finding new life thanks to contemporary tweaks. WRSMs have one major plus: their magnetic field can be controlled in real time, which provides engineers with more control over performance as well as regenerative braking.
Traditionally, however, WRSMs have used slip rings and brushes to deliver power to the rotating rotor. Those components degrade over time, keeping the motor from being more than that—until now.
BMW’s Rare-Earth-Free Motor: Classic Concept, Cutting-Edge Execution
BMW is at the front with an overhauled WRSM. In its fifth-gen electric motor—employed in vehicles such as the iX M60—rare-earth magnets have been entirely removed by the company. It employs a three-phase AC synchronous form with brushes and a commutator to power the rotor windings.
Typically, that configuration would introduce issues with wear and dust. But BMW engineers have encapsulated the brush assembly within a sealed compartment to avoid contamination and maximize lifespan. The reward? A motor providing up to 610 horsepower in Sport Boost mode, with enhanced heat management, increased energy density, and improved response—all without the use of rare-earth materials.
No Brushes, No Contact: MAHLE and Valeo’s High-Tech Leap
Not all companies are sticking with brushes. German automotive supplier MAHLE has developed a brushless, contactless system that transmits energy to the rotor wirelessly via inductive coupling. It’s like wireless charging, but for high-performance electric motors.
In 2024, MAHLE teamed up with French firm Valeo to bring this technology to premium EVs through a system they call iBEE (inner Brushless Electrical Excitation). It brings together MAHLE’s wireless power transmission technology and Valeo’s extensive experience in inverters and motor control. What does it add up to? Up to 350 kW peak power, no wear, and a carbon footprint minimized by more than 40% versus magnet-based motors. Prototypes are already undergoing testing, and so far, the early indications are encouraging.
Why This Shift Matters
Going magnet-free isn’t only an astute engineering step—it’s a strategic one. By reducing rare-earth use, automakers can save on production costs, become more sustainable, and diminish dependency on politically sensitive supply chains. And through gains in electronics, cooling, and motor architecture, these new motors are keeping pace—and sometimes surpassing—their magnet-laden equivalents.
What’s Next for Electric Motors
This shift is only just starting, but the pace is quickening quickly. BMW, MAHLE, Valeo, and more are demonstrating that high-performance EVs do not need to depend on rare earths. With ongoing advances in technology, magnet-free motors can be expected to become increasingly prevalent, particularly in mid- to upmarket EVs where efficiency and green credentials drive sales.
The future of electric cars isn’t only about batteries—it’s about what turns the wheels. And with the industry moving towards cleaner, more consistent, and more ethical alternatives, safe to say that the future of EVs will be powered by wiser motors without sacrificing performance or values.
