The Road to Sustainable Electric Motors for EVs: IDTechEx Analyzes Key Factors

IDTechEx analysis of the environmental impact of materials in various commercial EV motors. Source: IDTechEx

(IN BRIEF) Electric vehicles (EVs) are essential for decarbonizing the transport sector, yet concerns regarding the sustainability of materials used in their electric motors persist. A recent IDTechEx report predicts a demand for over 160 million electric motors annually by 2035, emphasizing the need for sustainable design. While stator materials remain largely consistent, rotor materials vary significantly, with rare earth permanent magnet motors commanding an 85% market share in 2023. However, these rare earths contribute to a higher environmental impact, raising questions about their sustainability. The report highlights that increasing the power density of motors can enhance efficiency and reduce battery size, ultimately minimizing material usage. Although the average number of motors in battery electric vehicles (BEVs) has increased by 13% since 2015 due to higher-performance configurations, there is a potential market for affordable single-motor BEVs. As battery materials have received more scrutiny, the report suggests that electric motors could also significantly enhance vehicle sustainability in the future.

(PRESS RELEASE) CAMBRIDGE, 10-Oct-2024 — /EuropaWire/ — Electric vehicles (EVs) are a key route to decarbonizing the transport sector. However, the materials used within them often come under scrutiny regarding their sustainability. As a key part of an EV’s drivetrain, considering the sustainability of electric motor designs is important when looking at the sustainable nature of a vehicle. A recent market report from market intelligence firm IDTechEx predicts the need for over 160 million electric motors per year by 2035, making some considerations for their design important if sustainability is the ultimate goal.

The impact of material choice

Dr James Edmondson, Research Director at IDTechEx, states that in the vast majority of cases, the materials used in the stator of electric motors in the EV market are very similar – the major difference comes down to the rotor materials. Rare earth permanent magnet motors make up the majority of the market, with IDTechEx finding they had an 85% market share in electric cars for 2023.

Dr Edmonson elaborates: “Of the materials considered for electric motors (steel, aluminum, copper), per kg, rare earths have the largest environmental impact when considering the potential for ozone depletion, global warming, acidification, eutrophication, and photochemical ozone creation. While they are a relatively small amount of the motor (less than 1-2kg), rare earth-containing motors tend to have a larger impact on the environment per kW of power compared to the rare earth-free alternatives, despite the fact magnet-free motors typically require greater amounts of other materials like copper. However, magnet-free motors may require other manufacturing steps that could increase energy consumption.”

Increasing power density and efficiency to improve sustainability

A more efficient motor means less energy is wasted driving the vehicle. This means less electricity from the grid being used, which, depending on the grid, could be significant in reducing CO2 output. Additionally, a more efficient motor means a smaller battery could be used to achieve the same vehicle range, therefore reducing material use and the environmental impact of the battery system.

A more power-dense motor will use less materials to achieve the same power output. Taking an extreme example of high power density with an axial flux motor, players interviewed by IDTechEx have claimed a power of 190kW can be achieved with less than 1.2kg of magnets or ~6.3 grams/kW. Compare this to a typical modern radial flux motor at around 10 grams/kW.

Do we need more motors?

IDTechEx’s research has found that the average number of motors used per BEV in 2023 was 13% higher than 2015, as more vehicles are deployed with dual, tri, and quad motor variants. Of course, having more motors in a vehicle will increase material utilization, not just for the motor but also for all of the associated electronics and thermal management components.

One could ask, how many consumers need more than one motor? It is certainly a nice luxury, and automakers often prefer selling these higher-specification vehicles that command a higher profit margin. This reduces the vehicle’s sustainability; however, if it means more people are willing to purchase a BEV, then this can be seen as a step in the right direction for the environment in general. IDTechEx believes that a key step for reinvigorating growth in the EV market will be the availability of low-cost models (especially in Europe) that will likely command a single-motor solution to keep costs down.

Sustainability is a core goal of most modern businesses, with many having net-zero goals in the not-too-distant future and entire departments dedicated to reducing the company’s environmental impact. As automakers try to make more profitable EVs, which will be a large factor in the decarbonization of road transport, the sustainability of EV components will often fall behind factors such as performance, efficiency, and price.

Additionally, more scrutiny is often given to the battery materials, and rightly so, given the quantities used compared to the motors. This is reflected in early regulations like the battery passport in Europe that requires the CO2 footprint of the battery to be reported. While the majority of the initial sustainability focus will be in this area, the motor could prove a significant route to improving vehicle sustainability in the future.

IDTechEx’s report, “Electric Motors for Electric Vehicles 2025-2035: Technologies, Materials, Markets, and Forecasts”, analyzes the current technology and materials landscape for electric motors in EVs and forecasts the future trends and demands for the next ten years. For more, please visit www.IDTechEx.com/Motors.

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Here are some frequently asked questions (FAQs) related to the sustainability of electric vehicles (EVs) and the insights from the IDTechEx report:

FAQs on Electric Vehicle Sustainability and Electric Motors

1. Why are electric vehicles (EVs) considered essential for decarbonizing the transport sector? EVs produce zero tailpipe emissions, making them a cleaner alternative to traditional internal combustion engine vehicles. They play a crucial role in reducing greenhouse gas emissions and air pollution, contributing to global efforts to combat climate change.

2. What materials are commonly used in the construction of electric motors for EVs? Electric motors typically utilize materials such as steel, aluminum, copper, and rare earth elements. The rotor materials, especially rare earth permanent magnets, significantly influence the motor’s performance and environmental impact.

3. What impact do rare earth materials have on the environment? Rare earth materials, while providing high performance in electric motors, have a larger environmental footprint per kilogram compared to other materials. They contribute to issues such as ozone depletion, global warming, and resource depletion due to their extraction and processing.

4. How many electric motors are expected to be needed in the future? The IDTechEx report predicts a demand for over 160 million electric motors annually by 2035, driven by the growing adoption of electric vehicles and the need for more efficient motor technologies.

5. How does increasing motor efficiency contribute to sustainability? More efficient motors waste less energy, resulting in lower electricity consumption and reduced CO2 emissions. Additionally, higher power density allows for smaller batteries, minimizing the environmental impact associated with battery production.

6. What trends are being observed in the number of motors used in battery electric vehicles (BEVs)? The average number of motors used per BEV has increased by 13% since 2015, as automakers introduce dual, tri, and quad-motor configurations for enhanced performance. This trend raises concerns about material utilization and sustainability.

7. How do consumer preferences influence the sustainability of EVs? While many consumers may prefer higher-performance vehicles with multiple motors, there is also a growing market for low-cost, single-motor models. Balancing performance with affordability can enhance the adoption of EVs and improve overall sustainability.

8. Why is there more scrutiny on battery materials compared to electric motors? Batteries typically use larger quantities of materials, leading to significant environmental concerns during extraction and processing. Early regulations, such as the European battery passport, focus on reporting the CO2 footprint of batteries, overshadowing the sustainability of motor components.

9. What recommendations does the IDTechEx report make for improving motor sustainability? The report highlights the importance of selecting sustainable materials for electric motors, increasing power density, and exploring alternative designs to reduce environmental impact while maintaining performance.

10. Where can I find more information on the technology and materials landscape for electric motors in EVs? For a comprehensive analysis of current technologies, materials, and future trends in electric motors for electric vehicles, you can refer to IDTechEx’s report titled “Electric Motors for Electric Vehicles 2025-2035.” More details are available at www.IDTechEx.com/Motors.

SOURCE: IDTechEx