Rare Earth-Free Next-generation High Power Density Electric Powertrain

Road transport produces around 1/4 of UK/Global carbon emissions and 1/3 of UK/Global NOx and particulate emissions (responsible for poor air quality/smog and associated adverse health effects such as respiratory disease - particularly in densely-populated urban areas) \[DFT2021\].

Electric Vehicles (EVs) form a key part of the UK government's net-zero strategy, which also includes plans to phase out new petrol/diesel cars by the 2030s. Many leading vehicle manufacturers have now publicly committed to an electric future.

UK and global consumer demand for EVs is rising rapidly, and governments/industry key players in developed economies worldwide are investing heavily in charging infrastructure, consumer incentives and domestic EV component supply chains.

The supply of key EV components needs to keep pace with demand to deliver net-zero ambitions in the automotive sector. The Lithium-Nickel-Cobalt supply chain is often cited as a potential bottleneck for EV batteries, but less widely-recognised is the rare-earth-element supply chain bottleneck for powertrains (motors and power electronics required to drive them efficiently).

Powertrains convert the chemical energy stored in batteries into kinetic/moving energy of the wheels through the control of electromagnetic energy - they are therefore central in driving overall EV performance, range and cost.

The vast majority of EV powertrains in use today rely on rare-earth-elements to deliver high propulsion performance (power and torque density) and power conversion efficiency levels. Powertrain performance and efficiency together determine range along with battery capacity/efficiency and vehicle weight.

High performance and range combined with affordability are critical to making EVs attractive to consumers versus familiar and trusted petrol/diesel cars. If access to rare-earth-elements becomes scarce (they are rare by definition), the cost of EV powertrains would increase significantly, and the performance and range of EVs would be considerably limited - putting the project of automotive electrification at risk.

Furthermore, rare-earth-element mining is associated with severe environmental pollution (including radioactive waste entering the atmosphere and water supplies as dust/runoff) and poor working conditions.

In response to this challenge, this project will progress the development of a unique and highly innovative rare-earth-free powertrain design, which matches current industry-leading levels of performance and efficiency.

This will support delivery of the considerable environmental benefits of EVs (climate change mitigation and air quality), without the downsides associated with rare-earth-element supply chains. Through this process, the outcomes of the project will additionally deliver a significant UK taxpayer return on investment, high-value manufacturing jobs and domestic EV supply chain security.