Rare-earth-free magnets could lead to motor ‘breakthrough’
19 September 2025 
A US company that has developed a technology for manufacturing powerful rare-earth-free magnets, has licensed a portfolio of patents for variable-flux motors (VFMs) which, it says, represent a transformative approach to electric machine design that has been untapped until now because of these motors’ demanding requirements for magnetic materials.
Minneapolis-based Niron Magnetics claims that combining the VFM designs with its iron nitride magnets will enable “next-generation electric motor performance” in applications including HVAC systems, robotics, pumps, compressors, appliances and automotive traction.
VFMs are said to eliminate the usual trade-off between low-speed and high-speed motor efficiency. This leads to benefits ranging from reduced power consumption in data centre cooling applications, to longer ranges and smaller battery packs in vehicle applications.
“Variable-flux motors have been built and proven before,” explains Daniel Hervén, CEO of the Swedish-headquartered engineering and motor design firm,
“Variable-flux motors have been built and proven before,” explains Daniel Hervén, CEO of the Swedish-headquartered engineering and motor design firm, Alvier Mechatronics, which is working with Niron to integrate its magnets into motors. “What’s held these motors back is the lack of an ideal material. Rare-earth magnets are not well-suited for this motor type.
“Until now,” he continues”, most VFM work was done with AlNiCo (aluminium nickel cobalt), but VFMs with AlNiCo magnets fall short of the performance needed for commercial use, and cobalt faces supply chain challenges. Iron nitride presents the opportunity to unlock VFM for mainstream commercial use.”
Niron predicts that combining its the licensed VFM patent portfolio with its rare-earth-free magnets, could lead to “unprecedented efficiency and performance improvements” in many applications.
“This licensing agreement is the result of decades of world-class motor research meeting the best of material science ingenuity to bring next-generation motor performance to commercial reality,” says Niron’s CEO, Jonathan Rowntree. “Our iron nitride technology provides the missing piece that accelerates this achievement into industrial scalability, enabling multiple ongoing customer projects that are focused on commercialising breakthrough technology.”
Niron Magnetics is scaling a world-first manufacturing process mass-producing permanent magnets based on its “breakthrough” material formulation. It will result in magnets that offer high magnetisation, and are free from rare-earths and other critical materials.
The US-sourced magnets therefore solve the problem of volatile rare-earth supply chains. Combined with the motor design expertise of Niron and its partners , the magnets “are poised to both deliver significant performance improvements and secure a strong American motor industrial base”.
Niron has recently broken ground on its first commercial production plant – a 190,000ft2 (17,650m2) facility in Sartell, Minnesota, that is due to open in 2017, and will be capable of producing 1,500 tons of permanent magnets a year. The site will create more than 175 jobs.
Niron opened a pilot plant in Minneapolis in 2024. Partners including Stellantis and Samsung have been sampling products from the pilot facility.
Niron Magnetics: LinkedIn
Alvier Mechatronics: LinkedIn
