Metal Trade Show | The Benefits of Replacing Copper and Rare Earth Elements with Aluminium in Electric Motors
According to Metal Trade Show, Newcastle-based electric motor manufacturer Advanced Electric Machines (AEM) has announced plans to replace copper and rare earth elements with aluminium in their products, citing aluminium's cost-effectiveness and energy efficiency.
“Dependence on rare earth elements and copper poses significant political and economic challenges and harms the environment,” said James Widmer, CEO and co-founder of AEM. “By replacing copper with aluminium, we can reduce coil costs by 89% while improving performance by 30%. This technology redefines how motors are manufactured, recycled, and integrated into sustainable mobility solutions,” he added.
Founded in 2017, AEM is dedicated to transforming electric vehicle motor technology. By replacing copper with aluminium and using designs entirely free of rare earth materials, this Newcastle University spinout aims to lower costs, enhance performance, and adopt fully recyclable and environmentally friendly technology.
Unlike traditional electric motors that rely on neodymium or dysprosium magnets, AEM offers an alternative that reduces dependence on rare earth elements and mitigates the environmental impact of their extraction.
Innovative Advantages
Tom Elliott, AEM’s Director of Business Development, highlighted the technical benefits of their approach: “By eliminating permanent magnets, we’ve eliminated the risks of demagnetization, making electronic drives safer and simplifying thermal management.”
AEM’s motors use HDSRM (High-Density Switched Reluctance Motor) technology, offering a lighter, more sustainable, and highly efficient all-aluminium motor. Key benefits include:
- 22% reduction in power loss
- Over 30% increase in continuous power output
- No magnetic losses, enabling higher efficiency at high speeds
- Compatibility with standard three-phase inverters, making it versatile for various applications
The motor operates smoothly even under high temperatures, with virtually no risk of demagnetization.
Real-World Testing and Applications
The HDSRM model has undergone over 3 million kilometers of real-world testing. Its technology is already being used in trucks, buses, and trains.
Currently, AEM is developing a new motor for cars and smaller vehicles, called SSR, which is still in its early development phase. The SSRD motor boasts:
- A maximum speed of 30,000 RPM
- Efficiency rates of up to 94%
Additionally, AEM engineers are working on special integrated electronic devices to further enhance the motor’s capabilities.