Axial-flux motor delivers V8 torque and challenges radial-flux machines

22 July 2025  

Orbis Electric says that its HaloDrive motor-generator delivers the same torque as a V8 engine

A US electric motor developer has announced an advanced axial flux motor-generator with a modular four-part architecture that includes an injection-moulded, oil-cooled plastic stator, and a tunable gearset, which multiplies mechanical output torque while reducing the need for magnetic materials such as rare-earths. California-based Orbis Electric says that its HaloDrive system outperforms conventional radial- and axial-flux machines, delivering strong performance, high efficiency (up to 97%), and easy configurability – while maintaining high torque and power density, with good thermal stability.

The motor has been designed primarily as an in-wheel drive for electric vehicles, but Orbis also envisages other applications, including industrial machinery, power generation, marine propulsion and drones. The design is protected by 28 issued patents, with another 22 pending.

With a simple alteration of the windings, the same housing can be used as a high-efficiency generator. This dual-use capability could cut inventory costs and allow OEMs to standardise on one electromechanical platform for different products and applications.

The motor can achieve a torque density of up to 115Nm/kg when using neodymium (rare-earth) materials – matching the torque of a V8 engine – and deliver up to 350Nm for 30 seconds when using alternative magnetic materials.

When used as an in-wheel motor, Orbis claims that its machine will cut drivetrain costs by up to 35% compared to radial-flux motor systems. The Santa Rosa company has been working with passenger vehicle manufacturers (including Volkswagen) to test its designs and says that the technology can reduce vehicle weights, while improving ranges by 20%.

Orbis has also been involved in pilot trials in which the HaloDrive operates as a generator, replacing the diesel generators used to power refrigeration systems in commercial trucks. As well as eliminating the need for diesel to power the refrigeration, the electric system is claimed to cost 90% less to operate. Installed on a truck’s driveshaft or an axle, the machine converts braking energy into electricity to power the refrigeration system. Orbis reports that in pilot trials, this configuration has improved the efficiency of one fleet by 61%.

The in-wheel motors will be available with one or two rotors. The 46kg single-rotor versions will deliver up to 100kW peak (53kW continuous) and 1,560Nm of torque. The 54kg dual-rotor versions will deliver up to 145kW peak (78kW continuous) and 3,000Nm of torque. Both versions are 428mm in diameter and have a top speed of 5,500 rpm. They operate from 96–800V supplies.

“Our vision with HaloDrive is to significantly advance how businesses transition to electrification by removing electric motor barriers such as deployment costs, material and manufacturability risks, and performance limitations,” says Orbis Electric’s CEO, Chance Claxton. “With HaloDrive, we offer a high-performance axial-flux motor that is not only highly efficient and powerful. but also environmentally sustainable.”

“Our approach with HaloDrive is – and always has been – about creating a motor that not only meets the immediate electrification needs across a range of industries, but is also compact and efficient enough to position businesses for future energy and sustainability standards,” adds Orbis’ founder and CTO, Marcus Hays. “This is something our engineering team of EV, aerospace, fabrication and environmental experts have spent years developing. We can achieve exceptional performance while also mitigating risks tied to rare-earth materials, ensuring consistent availability and pricing stability.”

Each of the HaloDrive’s four main components has been optimised for high-volume manufacturing, helping to bridge the cost gap with radial-flux designs. The modular design also supports rapid rescaling with minimal retooling. The oil-cooled polymer stator is said to cut weight, costs and complexity compared to wound iron cores, resulting in high efficiencies at low thermal loads.

Orbis says it is now looking for production partners for the HaloDrive, as well as OEM, fleet user and industrial customers.

Orbis Electric:  LinkedIn