MERCEDES-BENZ has commenced large-scale production of its long-awaited axial-flux electric motor, a breakthrough technology the German marque believes will redefine high-performance electric vehicles.
The compact, lightweight drive unit has entered series production at Mercedes-Benz’s Berlin-Marienfelde facility and will make its production vehicle debut in the upcoming Mercedes-AMG GT 4-Door Coupe.
The launch marks a significant milestone for Mercedes-Benz and its British engineering subsidiary YASA, whose axial-flux motor technology has been years in development before finally reaching automotive mass production.
Mercedes-Benz says the new motor offers substantially greater power and torque density than conventional radial-flux electric motors while occupying significantly less space.
The technology is central to AMG’s future electrification strategy, addressing one of the key challenges facing performance EVs – delivering sustained high outputs without excessive weight or thermal limitations.
“With the start of large-scale series production of the axial-flux motor in Berlin-Marienfelde, we are bringing a pioneering innovation for electro-mobility into industrial reality,” said Mercedes-Benz Group board member for production, quality, and supply chain management Michael Schiebe.
“In doing so, we are sending a strong signal of technological leadership, operational excellence and the transformation of the automotive industry in Germany.”
The Berlin-Marienfelde facility, founded in 1902 and Mercedes-Benz’s oldest production site, has been transformed into a centre of excellence for high-performance electric drive systems.
Production of the axial-flux motor spans approximately 30,000 square metres across three buildings and seven production lines.
Mercedes-Benz says the manufacturing process incorporates 98 individual production steps, including 65 processes new to the company and 35 believed to be world-first industrial applications.
Development of the manufacturing systems has generated more than 30 patent applications.
Among the technological highlights are high-precision laser welding of copper coils, AI-assisted quality monitoring systems, and advanced final assembly processes capable of managing magnetic forces approaching 900kg while maintaining tolerances below 0.1mm.
Unlike traditional radial-flux electric motors, where magnetic forces flow outward from the centre, axial-flux motors direct magnetic flux parallel to the rotational axis.
The result is a disc-shaped design in which the stator is sandwiched between two rotor assemblies, dramatically improving power density while reducing overall size and weight.
Mercedes-Benz says the front-mounted axial-flux motor used in the new AMG GT 4-Door Coupe measures less than 900mm in width, while the rear motors are approximately 80mm wide.
The compact packaging enables greater flexibility in vehicle design while delivering performance levels traditionally associated with much larger power units.
Mercedes-Benz acquired Oxford, UK-based YASA in 2021, and has since worked to adapt the company’s low-volume technology for automotive mass production.
The company says extensive redevelopment was required to meet the durability, performance and production-volume requirements expected of a modern Mercedes-AMG product.
Performance credentials appear substantial with Mercedes-AMG claiming the all-electric AMG GT 4-Door Coupe will accelerate from 0-100km/h in as little as 2.1 seconds and achieve a top speed of 300km/h when equipped with the optional Driver’s Package.
The technology was previewed last year in the Concept AMG GT XX development vehicle, which completed more than 40,000km of high-speed testing and established 25 long-distance records at Italy’s Nardo proving ground.
Industry analysts view the industrialisation of axial-flux technology as one of the most significant electric powertrain developments in recent years.
While the principle has existed for decades, challenges relating to manufacturing complexity, cost and durability have prevented widespread adoption.
Mercedes-Benz believes it has now solved those challenges, potentially giving the company a technological advantage in the emerging market for high-performance electric vehicles.
The production launch also reinforces Berlin-Marienfelde’s growing importance within the Mercedes-Benz manufacturing network.
Since 2022, the site has hosted the Mercedes-Benz Digital Factory Campus, serving as a development hub for advanced manufacturing technologies and digital production systems.
By combining electric drive development, intelligent automation and digital manufacturing, Mercedes-Benz says the facility will play a central role in transferring future technologies from prototype stage into full-scale production.