The search for alternatives to conventional electric motors , which are highly dependent on rare earth elements , has become a top priority for the automotive industry in Europe. In a landscape marked by pressure from Asian and American brands, as well as tensions in the international supply of raw materials, initiatives focused on developing electric motors without rare earth elements have gained more prominence than ever. Projects such as the European consortium HEFT, led from Spain, and the innovative industrial development of the Green Silence Group in Italy stand out, offering distinct but complementary solutions to this technological and strategic challenge.
Reducing dependence on critical materials is not only about economic or safety reasons, but also about promoting more environmentally friendly electric mobility . Through experimentation with new technologies, Europe aims to position itself competitively against giants like Tesla and major Chinese manufacturers.
Innovations for rare earth-free electric motors in Europe
One of the most striking developments comes from Spain, where a team from Mondragón University and several European partners are developing next-generation electric motors that largely eliminate the need for rare earth elements like neodymium. This project, part of the HEFT initiative and funded by the EU, aims to manufacture lighter, more powerful , and more environmentally friendly solutions , reducing the carbon footprint and facilitating recycling at the end of the motor's lifespan.
The main strategy has been to replace the traditional use of neodymium permanent magnets with cerium magnets , a less in-demand material, or to opt for designs that allow for easy removal and reuse of the magnets . Furthermore, the switch to fiberglass-reinforced plastic housings, instead of traditional aluminum, has resulted in a significant reduction in weight and emissions.
These engines also incorporate more optimized cooling circuits and an internal design that allows for higher revolutions and compact operation without penalizing power output.
Italy boosts the sector with reluctance motors
Meanwhile, the Green Silence Group in Italy has pursued a different technological approach, reviving and innovating on reluctance motors . This type of synchronous motor completely eliminates the need for permanent magnets, making it independent of rare earth elements. Its operating principle is based on the alternation of electromagnetic materials and air gaps in the rotor, optimizing energy efficiency without directly supplying power to the rotor.
By eliminating permanent magnets, manufacturing costs are significantly reduced , facilitating both recycling and environmental impact. This technology has proven versatile enough for applications beyond the automotive sector, adapting to industrial vehicles, agricultural machinery, and even silent robotics.
Measurable results and benefits: greater efficiency, lower costs, and lower impact
Tests carried out on the engines developed under the HEFT project have shown significant improvements compared to current commercial models, such as those used in the Fiat 500e or the Volkswagen ID.4. Some of the most notable findings are:
- Weight reduced by more than 59%.
- Up to 60% less rare earths employed in construction.
- Significant increases in engine torque in continuous operation, reaching values ​​up to 55% higher than certain models.
- Reduced volume and carbon footprint (up to 82%) thanks to new materials and processes.
- Un 20% cost savings in mass production (about 100.000 engines/year).
These advances demonstrate a significant push towards more efficient and sustainable mobility, promoting the development of technologies that are more economical and have a lower environmental impact. The recovery and reuse of critical components, such as magnets, also helps reduce waste and close the product life cycle.
Next steps: from the laboratory to series production
Current developments are in the final prototyping phase . In the case of the HEFT project, the plan is to manufacture several prototypes with different magnet combinations and designs to suit various vehicle categories. The short-term goal is to attract the interest of European manufacturers , who will be able to choose to integrate the entire drive system or adapt some of the innovations separately into their production lines.
Meanwhile, the Italian approach to reluctance motors continues to evolve, emphasizing modularity and adaptation to different needs , demonstrating that it is possible to achieve a high level of efficiency and performance without relying on rare earth elements.
These advances reflect a commitment to technologies that are less dependent on critical materials and to the sustainability of the sector. Through research and business collaboration, Europe seeks to position itself at the forefront of electric mobility. The consolidation of these innovations in the market could mark a significant turning point in reducing international dependence on strategic components.
