The World’s First Non-Metallic Electric Motor: A Groundbreaking Innovation
Imagine a world where electric motors are lighter, more sustainable, and perform better than ever before. MTC is making that a reality by creating the world’s first non-metallic motor—a revolutionary step towards redefining electric machine construction and performance.
The challenge
From cars and planes to industrial machinery and household appliances, motors power nearly everything. With these devices consuming almost 50% of global electricity, there’s an urgent need for radical innovation. However, current industrial demands are straining the supply of expensive and increasingly scare materials like rare earth magnets, electrical steel, and copper, often sourced from outside the UK in regions with challenging supply chains.
MTC engineers drive product innovation through their insatiable curiosity and a desire to impact society. With no prior experience in electric motor design, this profile provides a perfect platform for innovation, when combined with state-of-the-art manufacturing technologies, digital tools, and a cross-sectoral partnerships.
Seeing the future challenges for electric machines as an opportunity for positive change, The MTC and its team of design engineers started a trailblazing product and manufacturing innovation activity – to create the world’s first non-metallic motor.
MTC's solution
Looking to bridge the gap between industry and academia, MTC conducted an exhaustive evaluation of electric motor products and concepts.
The aim was to discover non-metallic material alternatives which provided a similar function or to find ways to eliminate components entirely. This liberating process uncovered advanced, cutting-edge technologies that, if scaled, could dramatically enhance motor performance and decrease reliance in volatile, environmentally damaging supply chains.
A bold new design concept was proposed, combining an unconventional motor topology with Carbon Nanotube (CNT) Yarn- replacing traditional copper or aluminium wire in motor windings. A detailed product development roadmap was then created and executed which considered: materials development, a commercial and sustainability assessment, and a design-make-test iterative loop which sought to continuously derisk and improve the non-metallic motor product.
Leveraging its expertise and collaboration with the University of Nottingham, and design tools from Siemens Digital Industries, MTC successfully brought the world’s first non-metallic motor to life.
The staggering opportunities for a non-metallic motor are far beyond our first expectations. This world’s first technology is a testament to how radical product innovation is possible when engineers are provided with groundbreaking manufacturing technologies to fuel their insatiable curiosity.
Dan Walton, Technology Manager – The MTC
The outcome
The initial phases of development have already revealed transformative benefits:
Unlocked performance
With exceptional high-frequency performance; reduced mass; and a higher performance ceiling than traditional materials.
Simpler supply chains
Elimination of critical minerals leads to decreased vulnerability to pricing fluctuations and the opportunity for a sovereign supply chain.
New environments
For applications in harsh environments needing compatibility to high-temperatures, corrosives, reactives, or even radiation.
To be able to deliver a non-metallic electric motor that can be manufactured on an industrial scale is an exciting prospect for UK manufacturing. Now we know what is potentially possible and the benefits, the next stage of the project is going to be essential in establishing a design that delivers a commercially viable, manufacturable product that produces high performance levels.
Chris Gerada, Professor of Electrical Machines – University of Nottingham
As of 2024, MTC continues to refine and enhance the non-metallic motor through prototyping and testing with an eye to the future scale-up of the design. Meanwhile, advances in Carbon Nanotube Yarn offer the potential to surpass all performance metrics of traditional copper and aluminium wound motors. Finally, MTC is discovering new applications, such as high-temperature motor and lightweight sensors, which expand the impact of this innovation beyond the original scope.
Please get in touch if you represent an organisation with an interest in radical innovation in electric machines, electro-mechanical devices, or scale-up of carbon nanotube yarn.
The MTC is now seeking partnership to further develop and then industrialise the Non-Metallic Motor and its accompanying technologies.
