A technical guide for CTOs on choosing axial flux motors for EV, Aviation, and Robotics. Compare torque density and scalability with Beyond Motors.

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Choosing the Perfect Axial Flux Motor for EVs, Aviation, Industrial Machines, and Robotics

As the global push for electrification transitions from "experimental" to "mission-critical," the choice of powertrain architecture has become the defining factor for project success. For CTOs and lead engineers, the primary challenge is no longer just finding a motor, but finding one that optimizes the specific constraints of their application—whether that is the weight sensitivity of an eVTOL or the torque requirements of a heavy industrial robot.

At Beyond Motors, we understand that a one-size-fits-all approach is a relic of the radial-flux era. The axial flux motor represents a shift toward application-specific engineering. Choosing the right one requires a deep dive into torque density, thermal management, and mechanical scalability.

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1. Electric Vehicles (EVs): Range through Efficiency

In the automotive sector, the "pancake" form factor of axial flux technology is fundamentally changing vehicle architecture. Because our Beyond Motors AXM series delivers 30-40% higher torque density, engineers can move the motor into the wheel hub or integrate it directly into low-profile chassis.

• The Key Metric: Continuous vs. Peak Torque. In our analysis of the Top 7 Things to Consider Before Purchasing an Axial Flux Motor, we highlight the "thermal trap." For EVs, you need a motor that maintains high efficiency (>96%) during sustained highway cruising, not just short bursts of acceleration.
• Recommendation: For high-performance automotive platforms, we recommend a modular approach using our stackable designs to reach desired torque levels while maintaining a thin axial profile.

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2. Aviation and UAVs: The 10 kW/kg Frontier

For electric aviation and drones, weight is the ultimate enemy. Every gram of motor weight is a gram of lost payload or battery capacity.

• Power Density: Our AXM series is designed to push the boundaries of 10 kW/kg power density. This makes axial flux the only viable solution for vertical take-off and landing (eVTOL) aircraft where high thrust-to-weight ratios are mandatory.
• Aerodynamic Integration: The disc-shaped geometry allows for a more streamlined integration into nacelles. As discussed in our Detailed Axial Flux Motor Performance and Efficiency Showdown, the shorter magnetic path reduces iron losses, which is critical for extending the flight time of high-altitude UAVs.

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3. Industrial Machines and Robotics: Precision and Power

Robotics and industrial automation require a unique blend of high torque at low speeds and exceptional thermal stability for 24/7 operation.

• Compact High Torque: In robotics, space is at a premium. The ability to generate massive torque in a slim volume allows for more compact joints and higher payload capacities.
• Thermal Control: Unlike radial motors that bury their heat-generating components, Beyond Motors uses a patent-pending cooling system that enables high-performance e-motors to run cooler for longer. This is essential for industrial machines where downtime is not an option and environmental heat can degrade traditional systems.

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Scalability: The "Stacking" Advantage

One of the most frequent questions we receive from lead engineers is how to scale a design for different vehicle variants. At Beyond Motors, we solved this with a stackable architecture. Instead of redesigning the entire drivetrain for a "Performance" model, you simply double or triple-stack the rotors.

This modularity allows companies to streamline their R&D and inventory while offering a wide range of power outputs from 50kW up to 1.2MW. This scalability is why the axial motor is truly the EV technology of the future.

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Engineering Your Solution

The "perfect" motor doesn't exist in a vacuum—it exists in your CAD files and your performance targets. Whether you are building a sub-100kg UAV or a multi-ton electric excavator, your choice of motor will define your product's competitive edge.

Get Your Technical Data Sheets:To see exactly how our motors perform under your specific project loads, use our configurator to request data on custom specs, sizing, or specific project requirements.

Start Your Configuration with the Beyond Motors Configurator