Texas Researchers Develop Rare Earth-Free High-Power Electric Motors Using Copper

A team of researchers at Texas A&M University has developed a groundbreaking electric motor that eliminates the need for rare earth materials, offering a more sustainable and cost-effective solution for high-power electric motors. The new design uses copper coils instead of the rare earth materials commonly used in the rotating parts of motors, addressing both environmental and economic challenges associated with traditional motor manufacturing.

Electric motors are essential components in a wide range of technologies, including electric vehicles, wind turbines, airplanes, and ships. However, most of these motors rely on rare earth materials, such as neodymium, to create powerful magnets for motor propulsion. The mining and extraction of rare earths are not only environmentally damaging but are also concentrated in a few countries, making them expensive and prone to supply chain disruptions.

The team received nearly $500,000 in funding from Texas A&M University’s Advancing Discovery to Market (ADM) Innovation Awards program. This funding will support the commercialization of the motor, with the team planning to establish their own company and expand the application of their innovation to sectors such as transportation and renewable energy.

Led by Dr. Hamid Toliyat, a professor in the Department of Electrical and Computer Engineering at Texas A&M, the team sought to find an alternative to rare earth materials for electric motor production. Working alongside Ph.D. student Mehdi Seyedi and postdoctoral researcher Dr. Dorsa Talebi, the researchers developed a motor that uses copper, an abundant and environmentally friendly material, to replace rare earth components.

“We aim to create a motor that is cost-effective, efficient, and sustainable without relying on rare earth materials,” Dr. Talebi said. “Rare earth mining is often unethical and energy-intensive, and the global supply of these materials is limited. Our motor addresses the urgent need for a solution that does not depend on these materials.”

In their two-year project, titled “Advancing Electric Vehicle Propulsion: High Power Rare-Earth-Free Electric Motor Development,” the team has replaced neodymium magnets with copper coils. This change not only makes the motor more accessible but also reduces costs, as copper is more readily available and less expensive than rare earth materials. By removing rare earths from the supply chain, the researchers are also reducing reliance on foreign markets for critical materials.

Dr. Toliyat emphasized that, in terms of power-to-weight ratio, the copper-based motor performs comparably to current motors that use rare earth materials. The team has already validated their concept through simulations and created a prototype to demonstrate its feasibility. They are working to ensure that the motor’s performance meets the standards of current electric and hybrid vehicle motors while competing with other rare earth-free alternatives.

“This technology has the potential to revolutionize industries like automotive and wind energy,” Dr. Talebi said. “By eliminating rare earth materials, we can create more sustainable solutions for the future.”