Low-cost, rare-earth-free UK motor has aluminium windings
3 April 2025 
A UK consortium has developed a prototype rare-earth-free synchronous reluctance motor which uses aluminium hairpin windings instead of copper, resulting in a robust, low-cost and sustainable alternative to conventional permanent magnet machines. Called the Alumotor, it has been designed to remove up to 60% of the cost of a standard motor.
The motor has been developed by a consortium led by the environmental and engineering consultancy, Ricardo, and including Aspire Engineering, Brandauer, the Warwick Manufacturing Group, Phoenix Scientific Industries and Global Technologies Racing. The project has been funded by the government’s Innovate UK organisation.
The oil-cooled, 214kW motor operates with a maximum efficiency above 92%, and is designed to power light commercial and off-highway vehicles, although it could be scaled to suit other applications.
The 400V motor is intended to address issues related to the environmental impact of materials for electric motors. As well as removing up to 12kg of rare-earth magnets, it is free from other critical raw materials such as cobalt.
“We are excited to be at the forefront of testing aluminium-hairpin windings, and are achieving strong performance data that will support future go-to-market activities,” says Dr Dragica Kostic-Perovic, Ricardo chief engineer responsible for the Alumotor project. “This is a significant development, showing true innovation, and supports our reputation as experts in the design and development of future sustainable technologies.”
