Rare-Earth Supply Chain Risks Drive Motor Technology Innovation
UK electric motor manufacturer YASA has announced it will develop two new axial flux motor designs under the UK government-funded Project Resilience, aimed at reducing or eliminating the use of rare-earth magnetic materials. The project is funded through the DRIVE35 Demonstrate competition by the Department for Business, Innovation, Science and Trade, and delivered in partnership with the Advanced Propulsion Centre UK (APC) and Innovate UK. YASA is required to complete a technology demonstrator prototype by September 17, 2026, to validate the new designs.
YASA highlights that the supply chain for rare-earth permanent magnets is highly concentrated in specific regions, exposing automotive manufacturers to risks such as export restrictions, price volatility, and supply disruptions. Heavy rare-earth elements like dysprosium and terbium are commonly used to enhance the high-temperature resistance of permanent magnets, ensuring stable performance in electric motors under high loads. YASA notes that the extraction and processing of these heavy rare-earth elements are not only technically challenging but also result in significant carbon emissions, posing environmental concerns. As a result, developing low-rare-earth or rare-earth-free motor technologies has become a critical step in mitigating supply chain risks and environmental impact.
Tom Hillman, Head of Motor Simulation at YASA, states that the electric vehicle market’s demand for motors is increasingly diverse, with different applications requiring varying balances of performance, efficiency, packaging, cost, and production volume. To address this, YASA will simultaneously develop two technology routes: the first is a heavy-rare-earth-free permanent-magnet design tailored for high-performance battery-electric and hybrid vehicles, aiming to maintain power density without increasing motor mass or package size. The second is a fully rare-earth-free axial flux technology designed for vehicle applications with differing performance, cost, and manufacturing requirements. Both designs will leverage YASA’s existing stator technology and introduce a modular motor architecture, allowing automakers to select rotor technologies flexibly based on their specific needs.