OptiMotor

Why is there a need for this type of research?

The global transition to electric mobility has highlighted significant limitations in conventional electric motor technologies. Synchronous reluctance motors (SynRMs) are a promising alternative to traditional motors, offering high efficiency without relying on expensive rare-earth permanent magnets. However, current SynRM designs are constrained by laminated metal construction, complex manufacturing processes, and difficulties in optimising magnetic flux management. These limitations result in high production costs, long lead times, and restricted scalability, particularly for small electric vehicles, drones, and e-bikes. Additionally, many conventional motors still rely on rare-earth elements, raising environmental concerns and supply chain vulnerabilities. There is a clear need for electric motors that are lightweight, cost-effective, highly efficient, environmentally sustainable, and capable of supporting the growing demand for electrified transport solutions.

The OptiMotor project addresses these challenges by developing next-generation SynRMs using advanced biopolymer-based composite materials and additive manufacturing. Custom filaments, incorporating ferromagnetic alloy particles and reinforcing fibres, are engineered for Fused Deposition Modelling (FDM), enabling complex rotor geometries that are impossible with traditional techniques. An AI-driven multi-objective optimisation workflow combines deep learning and computational physics models to determine the optimal distribution of ferromagnetic particles and rotor geometry. This integrated approach enhances performance, reduces manufacturing complexity, and eliminates the need for copper and rare-earth elements.

What this research will change

OptiMotor’s outcomes will benefit electric vehicle manufacturers, drone developers, e-bike producers, and the wider electrification sector by delivering motors that are more efficient, lightweight, and sustainable. The technology can be applied across a range of mobility platforms, contributing to reduced environmental impact, lower production costs, and improved user experience through quieter and smoother operation.

Role of the Brunel Composites Centre in this research

Brunel Composites Centre (BCC) plays a key role in the project by developing and characterising biopolymer-based composite filaments, evaluating their mechanical and magnetic performance, and supporting AI-driven optimisation of rotor design. BCC also contributes to validation, testing, and manufacturability assessment to ensure the solutions are scalable for industrial applications.

Project Partners

• FAR-UK Ltd (Coordinator)
• Brunel University London (Brunel Composites Centre)
• SDT Drive Technology 
• Technical University of Munich (TUM)
• Tecnaro GmbH