Axial Flux Motors Are Reshaping Movement, Manufacturing & Power Generation

Vehicles, industrial equipment and automated systems are using electric power more frequently. Electric and hybrid systems are evolving how industries move, build and operate. At the center of this evolution is a demand for compact, efficient and reliable motors. 

Radial flux motors power most electric machines. However, axial flux motors are critical innovations that provide higher performance in applications like passenger cars, heavy-duty equipment, factory automation and collaborative robotics.

By combining high torque density, compact geometry, and exceptional efficiency, axial flux motors are not just an incremental improvement—they are evolutionary possibilities in design and performance across multiple industry verticals.

Compact Design

Space for components is often sparse in vehicles, some equipment and robots. Whether the application is a passenger car, a construction vehicle, or a robotic arm, designers and engineers must balance power and form factor.

READ MORE: The Back-and-Forth on Linear Motors

Axial flux motors deliver the same or higher power and performance as radial flux designs while occupying less space. This geometry makes them ideal for applications where larger or longer motors would compromise design flexibility or not be a realistic option because of fit. 

In vehicles, this may mean improved aerodynamics. In automation, it allows for more compact robotic joints. In industrial equipment, manufacturers can fit high-torque drives into already tight powertrain layouts.

High Torque Density

Axial flux motors have high torque density, a measure of the torque-carrying capability of a mechanical component, the ratio of torque capability to volume expressed in units of torque per volume. Their larger diameter and efficient magnetic flux path provide higher torque density than radial flux motors. This is critical in applications where strength and precision must coexist.

In electric vehicles, higher torque density means faster acceleration and stronger performance without increasing motor size. For off-highway equipment, the torque density affects the ability to handle heavy loads while maintaining energy efficiency. In automation, robotic grippers, exoskeletons and mobile robots benefit from stronger yet smaller drives.

Providing more torque per kilogram, axial flux motors reduce system weight and free up space for batteries, sensors, or additional payload.

Increased Efficiency

Electrification success is measured by performance and efficiency. Every watt saved extends range, runtime and return on investment. Axial flux motors are more efficient because of their shorter magnetic flux path and reduced copper winding length.

For electric vehicles, improved efficiency contributes directly to longer driving ranges. In buses and municipal fleets, it reduces energy costs and supports sustainable transportation goals. 

READ MORE: Materials Selection in Precision Mechanical Components 

In mobile robots and automated guided vehicles (AGVs), higher efficiency allows for longer operation per charge and fewer interruptions for recharging. Industrial equipment also benefits from reduced parasitic losses, lowering total cost of ownership. As manufacturers and operators seek to maximize productivity while minimizing emissions and energy use, efficiency gains from axial flux motors represent a major advantage.

Precision Motion Control

Automation depends on precise, repeatable motion. Whether it is a pick-and-place robot on an assembly line, an autonomous welding arm, or a surgical robot operating at sub-millimeter accuracy, the quality of motor control determines the success of the task.

When paired with advanced inverters, axial flux motors enable exceptionally smooth and accurate control of speed and position. Their design reduces torque ripple and cogging torque, allowing robots and automated systems to achieve finer movements with less vibration. This translates into higher quality output, reduced material waste, and safer interactions with humans in collaborative environments.

Precision motion also matters in vehicles and equipment. Smooth driving, regenerative braking, and advanced traction control are enhanced by the predictable torque of axial flux motors.

Thermal Management & Reliability

Reliability is critical in vehicles, heavy equipment and automated systems that must operate continuously under demanding conditions. Heat is a threat to motor performance. However, axial flux designs offer a natural, thermal management advantage.

Because of their flat geometry, axial flux motors expose more surface area for cooling. This enables faster heat dissipation compared to radial flux motors. The result is improved durability, longer service life and the ability to maintain performance in high-load or continuous-duty cycles.

For electric buses and trucks, better thermal management supports reliable operation in urban areas. For industrial robots and automation lines, it reduces unplanned downtime. For agricultural and construction machinery, it ensures high performance in harsh environments.

Compact Axial Flux Motor Enables Power-Dense EV Charging Generators

A manufacturer of medium-sized, fixed generators, designed for independent or grid-supplement electric vehicle (EV) charging needed help. The generators needed to be compact, scalable and efficient enough for critical infrastructure and other applications.

READ MORE: Axial Flux Motor Topology Signals Next Generation of Electric Motors

To meet these requirements, the engineering team sought a high-performance electric motor that could operate as a permanent magnet generator (PMG) within the charging system.

The application had strict constraints:

• Size. The motor had to fit within a tightly packaged enclosure
• Weight. The complete assembly, including the PMG, needed to stay under 500 kg.
• Power density. High output per unit volume was critical to maintain generator performance

To solve this, the manufacturer collaborated with an electrification expert, who suggested an axial flux motor with a double stack layout (see image below). The axial flux motor was the ideal solution for the limited space because of its short axial length and high power density. The selected motor’s specifications were: 

• Maximum speed – 3,700 rpm
• Continuous maximum torque – 375 Newton meters (Nm)
• Maximum torque, at 20 seconds (s) – 875 Nm
• Continuous maximum power 120 kilowatts (kW)
• Maximum power, at 20 s, – 310 kW
• Maximum continuous current – 220 Arms

During rigorous testing, the axial flux motor exceeded performance expectations when integrated as the PMG. It delivered the necessary electrical output efficiently, while conforming to tight spatial and weight constraints.  The generator manufacturer demonstrated the enhanced unit to major EV fleet operators, showcasing its potential for next-generation, grid-independent charging infrastructure.

Efficiency and Performance in Compact Design

Electrification and automation demand solutions that provide efficiency, performance, and reliability. Axial flux motors meet these challenges by combining compact form, high torque density, superior efficiency and effective thermal performance.

From vehicles to heavy-duty equipment to industrial robotics, axial flux technology is transforming how industries move and manufacture. Axial flux motor adoption is not just a response to today’s performance needs but an investment in sustainability, productivity, and innovation. As electrification accelerates, axial flux motors will be a cornerstone technology for movement and manufacturing.