Deep dive into custom in-wheel axial flux motors. Learn how Beyond Motors achieves 10kW/kg and 30-40% higher torque density for next-gen EV propulsion.
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Deep dive into custom in-wheel axial flux motors. Learn how Beyond Motors achieves 10kW/kg and 30-40% higher torque density for next-gen EV propulsion.
The automotive industry is currently witnessing a paradigm shift from centralized drivetrains to distributed, high-authority propulsion. For CTOs and Lead Engineers, the "In-Wheel Motor" (IWM) promise is the ultimate prize: total torque vectoring, maximized cabin volume, and the elimination of heavy mechanical differentials.
However, standard radial motors often fail in this application due to the "unsprung mass" penalty and volumetric constraints of the wheel rim. At Beyond Motors, we have re-engineered this concept from the ground up. By utilizing a bespoke axial flux motor architecture, we are enabling a generation of vehicles that are lighter, more agile, and fundamentally more efficient.
In an in-wheel application, the motor must compete for space with braking systems, steering knuckles, and suspension components. Traditional radial motors are long and cylindrical, forcing engineers to choose between a wider vehicle track or compromised suspension geometry.
The "pancake" form factor of our Beyond Motors AXM series is not just an aesthetic choice—it is a mathematical imperative. In a radial motor, torque scales with the square of the diameter (D2). In an axial flux machine, torque scales with the cube of the diameter (D3).
This allows us to achieve 30-40% higher torque density within the flat envelope of a standard 18-inch or 20-inch rim. By moving the active magnetic material to a larger average radius, we provide the high low-end torque required for direct-drive propulsion, eliminating the need for heavy, high-maintenance reduction gearboxes.
The primary technical critique of in-wheel systems is the increase in unsprung mass, which can negatively impact ride quality and tire contact patches. To mitigate this, the motor must be exceptionally light without sacrificing output.
At Beyond Motors, we utilize a yokeless and segmented armature (YASA) topology. By stripping away the heavy iron yoke found in legacy motors, we achieve a world-class power-to-weight ratio. Our high-performance e-motors deliver up to 10 kW/kg power density.
For a technical founder, this means the weight added to the wheel hub is often offset by the weight removed from the chassis (drive shafts, axles, and differentials), resulting in a net-neutral or even positive impact on vehicle dynamics.
In-wheel motors operate in one of the most hostile environments on a vehicle—subjected to brake heat, road debris, and restricted airflow. Standard air-cooled hub motors frequently "derate" (reduce power) within minutes of spirited driving.
We have engineered a patent-pending water cooling system that targets heat at the source: the stator windings. By integrating the cooling loop directly into the motor’s internal architecture, we maintain an efficiency island of >96% even under heavy load. This thermal stability is critical for:
No two EV platforms are identical. A low-floor urban delivery van has radically different torque requirements than a high-performance grand tourer or a tactical UAV.
The Beyond Motors advantage lies in our ability to provide custom specs, sizing, or specific project requirements. Whether you need a specific voltage matching for an 800V silicon carbide (SiC) inverter or a custom hub-face for a specific wheel bearing assembly, our modular AXM platform is designed for rapid, bespoke optimization.
Distributed drive is the only path to the next level of vehicle intelligence. By leveraging the torque density and packaging freedom of axial flux technology, Beyond Motors is providing the hardware necessary to turn "software-defined vehicles" into a physical reality.
Ready to simulate your next-gen drivetrain?We invite you to use the Beyond Motors Configurator to input your specific rim constraints, torque targets, and RPM requirements to receive a personalized performance data sheet.
