E-Drive Are Axial Flux Motors the Future of Efficient Electromobility?

Related Vendors

SWD AG

FAULHABER Drive Systems

Wuxi InfiMotion Technology Co., Ltd.

Axial flux motors are considered a particularly power-dense and efficient alternative to radial flux drives. Their potential for electromobility is enormous: smaller sizes, higher torques, and improved energy utilization. However, industrial implementation also faces challenges.

Axial flux motors are characterized by high power density, compact construction, and high efficiency. "For e-mobility, this means more power in the same installation space and more efficient energy usage," explains Thomas Stäuble, CEO of SWD AG, a Swiss specialist in stator and rotor technology. At the same time, the design allows for more flexible integration into various vehicle concepts. This is particularly important at a time when automakers are searching for solutions to increase range while reducing costs. Axial flux motors open up new possibilities by delivering high torque with low mass due to their design.

The axial flux motor has been technologically known for a long time, but only now are we moving fully into industrialization and mass production.

Thomas Stäuble, CEO of SWD AG

New Processes in Manufacturing Required

But these advantages also come with specific requirements. The geometry of the electrical steel sheets requires new processes in manufacturing. "The axial flux motor has been technologically known for a long time, but only now are we moving fully into industrialization and mass production," explains Stäuble.

The lack of standardization and solutions further exacerbates the challenges. "Radial flux motors are based on decades of optimized manufacturing processes. Axial flux concepts, on the other hand, must be rethought from the ground up in many steps," emphasizes Stäuble. Traditional large presses quickly reach their limits, both technically and economically. Therefore, manufacturing technologies must be developed that meet the specific requirements while enabling the transition from prototype production to stable series processes.

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Hurdles on the Way to Production

The greatest obstacles lie in transitioning prototype processes into industrial standards. While individual solutions may suffice in the lab or in prototype production, OEMs in series production demand process stability and scalability. Tool design, material handling, and quality assurance must be tailored to entirely new geometries. "OEMs expect consistent quality across large quantities," explains Stäuble. In addition, short cycle times and a rapid ramp-up from small-scale to large-scale production are critical.

Scalability in particular poses problems for many companies. Traditional manufacturing systems are optimized for a specific quantity and geometry but are hardly adaptable. This makes the introduction of new technologies like axial flux motors additionally a question of investment. Thus, a dilemma arises that is difficult to solve without modular manufacturing concepts.

A modular system allows manufacturing lines to be built step by step and expanded as needed.

Thomas Stäuble, CEO of SWD AG

Modular Special-Purpose Machines As the Key to Series Production

This is precisely where SWD AG's modular machine concepts come into play. SWD AG develops production solutions specifically tailored to axial flux components. "A modular system allows manufacturing lines to be built up step by step and expanded as needed," says Stäuble. This makes scaling very simple; each expansion stage is based on the same tools and enables series-grade laminated cores. This significantly lowers investment barriers, as companies can produce using series processes right from the start and later scale production flexibly. For OEMs, this means they can enter the market with new technologies risk-free while dynamically adjusting their production capacities.

Specialized process modules are used for this:

• innovative stamping and tooling concepts,
• precise stack formation modules,
• high-strength bonding and joining techniques as well as
• integrated testing and measurement systems.

"The combination of these modules allows manufacturing lines to be tailored to specific requirements while achieving the highest level of process stability," adds Stäuble. This creates a production system that remains flexible and adaptable not just for today but also in the future.

Quality Assurance And Reproducibility

For OEMs in the automotive sector, quality is the decisive criterion. A defective component not only incurs immense costs but also damages reputation. SWD therefore relies on comprehensive testing and measurement technology already implemented within the process modules. "Each production stage is continuously monitored, deviations are immediately detected and corrected," explains Stäuble. Automated sensors, tactile and electromagnetic measurements, as well as data-based evaluations ensure adherence to the required tolerances and limits. These real-time controls guarantee that quality remains consistent even at high production volumes.

Furthermore, systematic data collection opens up new opportunities: production data can not only be traced but also used for process optimizations. "With data-based evaluations, patterns and trends can be identified and utilized for continuous improvements," says Stäuble. This not only ensures quality assurance but also lays the foundation for predictive maintenance and long-term optimizations.

Electromobility Demands Flexible Production Capacities

A dynamic market like e-mobility also demands flexible production capacities. "Our modular approach allows production lines to be initially built on a smaller scale and then expanded step by step, or we can use one of our own production lines," says Stäuble. This enables investments to be closely tied to market developments. It ensures both future security and adaptability. This flexibility is particularly crucial for OEMs operating in a highly competitive market. It allows them to bring new vehicle concepts to market quickly without the risk of significant misinvestments.

The possibility for expansion includes not only the number of production lines but also their technological capabilities. New adhesive technologies, alternative materials, or additional testing methods can be integrated. This creates a future-proof production system that grows with the requirements. In the future, the location of manufacturing can also be defined flexibly. The compact, fully automated production lines can be installed directly where the components are needed. Thus, manufacturing no longer has to be exclusively at the supplier but allows the OEM to become the manufacturer with these machines, thereby increasing their value-added depth.

Our projects demonstrate that the industrial mass production of axial flux motors is a reality today with the right technologies and processes.

Thomas Stäuble, CEO of SWD AG

Series Processes for Axial Flux Components Successfully Implemented

SWD has already implemented projects with renowned automotive manufacturers. Axial flux components were successfully transitioned into series production processes. Modular production lines for laminated cores met not only the quality and reproducibility requirements but also the necessary flexibility. "Our projects demonstrate that the industrial series production of axial flux motors is a reality today with the right technologies and processes," says Stäuble.

Further development will be strongly influenced by automation, digitalization, and sustainability. AI-supported quality assurance, predictive maintenance, and data-driven process optimization will become increasingly important. At the same time, resource-efficient manufacturing, energy-efficient processes, and circular economy practices will gain significance. "We are continuously advancing our modular machine architecture to optimally reflect these trends and make series production even more efficient and sustainable," explains Stäuble.

Axial Flux Motors Also Interesting for Aviation

Furthermore, new fields of application are emerging: axial flux motors are not only interesting for passenger cars but also for other vehicle concepts or aviation. Each of these applications presents specific requirements for performance, weight, and efficiency; however, they all share the fact that these requirements can be particularly well met with modular production systems. Combined with global sustainability goals, this will further increase the pressure for innovation in the coming years.

Axial flux motors offer enormous potential for e-mobility—but their industrial implementation is complex. With modular machine concepts and specialized process modules, companies like SWD achieve the breakthrough to series production. OEMs benefit from flexibility, scalability, high quality, and sustainable processes. Projects from practical applications show that this technology is no longer just a vision for the future but has already arrived in industrial practice. This makes axial flux components a realistic and competitive option for the e-mobility of the future—a step that can significantly advance not only the industry but also the ecological transformation.

Patrick Schulze is a journalist for Wordfinder.

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