New e-motor from Ricardo aims to redefine EV powertrain sustainability

Engineering consultancy Ricardo has taken a big step in rethinking electric propulsion with the unveiling of Alumotor, a high-efficiency, rare earth-free electric motor. Their solution could help reshape how automakers approach sustainability and cost in EV design.

Presented at the UKRI Materials and Manufacturing Showcase 2025 in London, Alumotor is the product of a consortium project led by Ricardo and funded by Innovate UK.

The oil-cooled, 214 kW synchronous reluctance motor marks a notable departure from traditional electric powertrains. It eliminates rare earth elements and copper, both of which pose environmental and economic concerns for the automotive industry.

Aluminum instead of copper

What’s the substitute, then? Well, instead, Alumotor features aluminum hairpin windings — a material choice that reduces both cost and reliance on critical raw materials such as cobalt.

Tesla and Porsche also use hairpin windings, but they are still made from copper and built in a much more complex fashion. Ricardo’s project is best viewed as an alternative approach to reducing motor size, cost, and weight while boosting efficiency rather than being just another take on the rectangular ‘hairpin’ stator winding design like that from Porsche and Tesla.

With maximum efficiency reported at over 92%, the Ricardo motor has been designed for use in light commercial vehicles and off-highway applications. However, Ricardo claims it is scalable and can fit a wide range of mobility solutions.

Ethical concerns 

“We’re excited to be at the forefront of testing aluminum hairpin windings and are achieving strong performance data that will support future go-to-market activities,” said Dr. Dragica Kostic-Perovic, Ricardo’s Chief Engineer overseeing the Alumotor project. “This is a significant development that supports our reputation as leaders in sustainable technology innovation.”

The Alumotor comes amid growing industry pressure to reduce dependence on materials with complex and sometimes controversial supply chains. Rare earth elements, primarily sourced from a few countries, have sparked geopolitical and ethical concerns. Ricardo’s response is technological and strategic, with the company eyeing circular economy initiatives.

Alumotor is not Ricardo’s first foray into rare earth-free propulsion. The company previously developed an 85 kW synchronous reluctance prototype under the RapidSR project, which was also funded by Innovate UK and involved Jaguar Land Rover. 

Market-ready solution

Dr. Will Drury, team leader for electric machines at Ricardo, said the RapidSR concept has served as a valuable foundation. “By combining simulation technology with advanced machine design, we’ve created a next-generation motor that balances performance, packaging, and affordability.”

Ricardo now sees Alumotor as a credible step forward from concept to market-ready solution. With both performance and environmental benchmarks in mind, the company is positioning the new motor as a breakthrough not only in engineering.

“It’s about reducing our dependence on increasingly difficult-to-source materials and enabling a more sustainable EV industry,” concluded Paul Rivera, Managing Director of Ricardo’s hybrid and EV systems business.