When Mercedes-Benz first equipped its AMG all-electric supercar with a self-developed high-performance axial flux motor, Xiaomi’s U7 was also reported to be testing similar technology. Why are these two companies, with very different backgrounds, exploring this unconventional approach at the same time? Could axial flux motors become the core drive technology for next-generation electric vehicles?

Performance Changes Driven by Structural Differences

Most electric vehicles today still rely on radial flux motors, where the magnetic field is distributed along the rotor radius. In contrast, axial flux motors direct the magnetic field along the motor’s axial direction, with the stator and rotor arranged in a disc-like stacked structure.

This fundamentally different magnetic layout delivers several key advantages: higher power density, a shorter axial length, and lower rotor inertia. These characteristics make axial flux motors highly promising for high-performance EV drives and compact powertrain applications.

Manufacturing Challenges Have Long Prevented Mass Production

Although the principles behind axial flux motors are well-established, they have struggled to enter large-scale automotive production due to several manufacturing constraints. Their dual-stator or multi-disc structure demands extremely high coaxial assembly accuracy— even minor deviations can lead to operational instability. Additionally, hairpin winding must be formed within a narrow annular space, where traditional winding processes are difficult to apply.

High-strength magnetic materials also introduce assembly challenges, as magnetic forces require precise force control and real-time monitoring. Meanwhile, thermal concentration in the motor’s center makes the cooling system design significantly more complex.

Historically, axial flux motors relied heavily on manual or semi-automatic production, making it difficult to achieve the consistency, cycle time, and cost efficiency required by the automotive industry.

Technological Progress Is Accelerating Industrial Adoption

In recent years, advancements in intelligent manufacturing equipment have made large-scale production of axial flux motors increasingly feasible. High-precision vision guidance, flexible assembly robots, and mature closed-loop control systems are enabling automation in processes that once relied heavily on manual work.

At the same time, vehicle platforms are evolving. High-voltage electrical architectures demand higher efficiency from the drive system, while new chassis designs impose stricter requirements on motor size and packaging. These shifts have renewed industry interest in axial flux technology.

Today, several OEMs have already deployed axial flux motors in premium EV models, and some Chinese e-drive manufacturers are exploring their use in mass-market passenger vehicles. This marks an important transition: the industry is moving from questioning whether the technology can be built to focusing on how it can be mass-produced.

However, even with a viable technical route, scaling axial flux motors for mass production still faces several hurdles:

Manufacturing costs remain significantly higher than mainstream solutions.

Lack of long-term real-vehicle data, meaning durability and reliability validation is not yet complete.

After-sales service and recycling systems are not fully established, creating lifecycle concerns for OEMs.

In the cost-sensitive mass market, its performance advantages are not enough to justify the price premium.

As a result, axial flux motors are more likely to be adopted first in high-end models or specific application scenarios rather than replacing today’s dominant radial-flux architecture.

Overall, axial flux motors are unlikely to become a universal solution for all EVs in the near term. But in applications that demand high power density, tight packaging, or higher system integration, they have the potential to become a key option. Their future development will depend on manufacturing maturity, supply-chain readiness, and whether OEMs recognize their system-level value.

Ultimately, the core challenge is not the motor design itself—but whether it can be manufactured consistently, efficiently, and at scale.

With more than a decade of expertise in intelligent motor manufacturing equipment, Honest Automation has delivered automated production lines for multiple categories of automotive motors. Leveraging our capabilities in hairpin forming, precision assembly, and in-process quality control, we help e-drive manufacturers evaluate the mass-production roadmap for axial flux motors and jointly address the challenges of next-generation electric drive systems.