Explore advanced simulation and geometry optimization for custom axial flux motor development. Learn how Beyond Motors hits 10kW/kg and high torque density.

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Custom Axial Flux Motor Development: Advanced Simulations and Geometry Optimization Procedures

In the high-stakes engineering of 2026, the transition from prototype to production for electric propulsion systems is increasingly defined by the fidelity of the digital twin. For CTOs and Lead Engineers in the automotive, nautical, and aerospace sectors, "off-the-shelf" solutions often fall short of specific volumetric and performance targets.

At Beyond Motors, we have refined a rigorous custom motor development workflow. By utilizing advanced multi-physics simulations and automated geometry optimization, we deliver bespoke high-performance e-motors that push the boundaries of torque density and thermal efficiency.

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1. High-Fidelity Multi-Physics Simulations

Designing an axial flux motor involves complex 3D magnetic flux paths that traditional 2D analytical models cannot accurately capture. Our engineering process begins with high-fidelity Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD).

Electromagnetic FEA (3D Magnetic Flux)

We utilize 3D electromagnetic simulations to analyze magnetic saturation and flux leakage in the unique "pancake" geometry. By precisely modeling the interaction between the permanent magnets and the stator teeth, we optimize the air gap flux density. This ensures that every gram of active material contributes to maximizing the torque density, often achieving a 30-40% advantage over traditional radial designs.

Conjugate Heat Transfer (CHT) CFD

Heat is the primary constraint on continuous power. Our simulations assess our patent-pending water cooling system by modeling the fluid dynamics within internal cooling channels. We perform sensitivity analyses on different stator-carrier materials to ensure winding temperatures remain within optimal ranges even under peak load, enabling our motors to hit a 10 kW/kg power density without thermal derating.

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2. Automated Geometry Optimization Procedures

To reach the "Pareto front"—the perfect trade-off between weight, efficiency, and torque—we move beyond manual design iterations. Our proprietary optimization algorithms evaluate thousands of design candidates in hours.

• Parametric Model Build-up: We start with a fully parametric model build-up where variables such as pole-arc coefficients, tooth width, and magnet thickness are adjusted dynamically.
• Genetic Algorithms & Cuckoo Search: These procedures allow us to minimize cogging torque and torque ripple while simultaneously maximizing average output torque.
• Structural Reliability: Advanced mechanical simulations ensure the rotor can withstand the immense centrifugal forces and unbalanced axial attraction forces inherent in high-speed axial flux machines.

[Image: Visualization of FEA Magnetic Flux Density and CFD Thermal Contours]

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3. The Path from Simulation to Prototype

Our development cycle is designed for speed. By relying on robust simulation data, we significantly reduce the need for multiple physical prototyping rounds.

1. Alignment: We define the target duty cycle (e.g., eVTOL takeoff vs. cruise).
2. Simulation & Optimization: Multi-objective optimization balances efficiency and mass.
3. CAD & 3D Validation: Final mechanical design and integration check.
4. Rapid Prototyping: Delivery of the first functional motor in less than two months.

This streamlined process is why the Beyond Motors AXM series is the preferred choice for innovators who need high-authority propulsion on tight R&D schedules.

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Engineer Your Edge with Beyond Motors

The future of e-mobility isn't found in standard catalogues; it is engineered through simulation and precision. Whether you are scaling a powertrain for a luxury EV or a heavy-lift drone, our team provides the electromagnetic and thermal expertise to ensure your motor is a record-breaker.

Ready to start your custom development?If your project requires custom specs, sizing, or specific project requirements, use our technical portal to provide your constraints. Our team will utilize our optimization procedures to generate a personalized performance data sheet.

Start Your Custom Configuration via the Beyond Motors Configurator

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