{"id":109004,"date":"2025-12-18T14:30:04","date_gmt":"2025-12-18T14:30:04","guid":{"rendered":"https:\/\/www.simscale.com\/?page_id=109004"},"modified":"2026-02-19T13:30:04","modified_gmt":"2026-02-19T13:30:04","slug":"emil-motors-high-performance-ev-drives","status":"publish","type":"page","link":"https:\/\/www.simscale.com\/customers\/emil-motors-high-performance-ev-drives\/","title":{"rendered":"Emil Motors &#8211; High-Performance EV Drives"},"content":{"rendered":"\n<div>\n<style>\np {\n    font-size: 18px ;\n    line-height: 35px;\n    margin-bottom: 1.5em;\n}\nh2 { \n    font-size: 44px !important;\n}\n<\/style>\n<\/div>\n\n\n\n<div>\n<div class=\"gb-element-b1904b06\">\n<div class=\"gb-element-31350e07\">\n<div class=\"gb-element-51d29773\"><div class=\"yoast-breadcrumbs\"><span><span><a href=\"https:\/\/www.simscale.com\/\">Home<\/a><\/span> \u00bb <span><a href=\"https:\/\/www.simscale.com\/customers\/\">Customers<\/a><\/span> \u00bb <span class=\"breadcrumb_last\" aria-current=\"page\">Emil Motors &#8211; High-Performance EV Drives<\/span><\/span><\/div><\/div>\n<\/div>\n<\/div>\n<\/div>\n\n\n\n<div class=\"gb-element-a1ba63a4\" style=\"--inline-bg-image: url(https:\/\/frontend-assets.simscale.com\/media\/2025\/10\/product-background-svg.svg)\">\n<div class=\"gb-element-3e3f3809\">\n<div class=\"gb-element-b775d3a3\">\n<img loading=\"lazy\" decoding=\"async\" width=\"86\" height=\"50\" class=\"gb-media-c7dd2f5b\" alt=\"Emil Motors Logo\" src=\"https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/emil_motors_logo_1x.webp\"\/>\n\n\n\n<h1 class=\"gb-text gb-text-58a14c4d\"><strong>Emil Motors &#8211; Engineering a Magnet-Free Future for High-Performance EV Drives<\/strong><\/h1>\n<\/div>\n\n\n\n<div class=\"gb-element-03595def\">\n<div class=\"gb-element-914a8d89\">\n<div class=\"gb-element-c0babf30\">\n<img loading=\"lazy\" decoding=\"async\" width=\"80\" height=\"67\" class=\"gb-media-4f48e54e\" alt=\"Cost Reduction Icon\" src=\"https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/Cost-Reduction.svg\"\/>\n<\/div>\n\n\n\n<div>\n<span class=\"gb-text gb-text-c6b032df\">50% cost saving over legacy tools<\/span>\n<\/div>\n<\/div>\n\n\n\n<div class=\"gb-element-cfd9581e\">\n<div>\n<img loading=\"lazy\" decoding=\"async\" width=\"89\" height=\"68\" class=\"gb-media-524892be\" alt=\"Accelerate Development Icon\" src=\"https:\/\/frontend-assets.simscale.com\/media\/2025\/09\/respond-faster-icon.svg\"\/>\n<\/div>\n\n\n\n<div>\n<span class=\"gb-text gb-text-dd915ff7\">2x acceleration of development cycles<\/span>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n\n\n\n<div class=\"gb-element-56b0347a\">\n<div class=\"gb-element-1235f9fb\">\n<div class=\"gb-element-74368187\">\n<div class=\"gb-element-4f23639b\">\n<div class=\"gb-element-067668ed\">\n<h2 class=\"gb-text gb-text-96e8d1fd\">Challenges<\/h2>\n\n\n\n<li class=\"gb-text gb-text-6ba90b7e\">Timely multiphysics modeling of novel induction motor design to drive rapid design process.<\/li>\n\n\n\n<li class=\"gb-text gb-text-ff9133e3\">Ensuring structural integrity of the dual-rotor assembly at high operational speeds<\/li>\n\n\n\n<li class=\"gb-text gb-text-9a1e1f3f\">Identifying invisible &#8220;stray losses&#8221; caused by magnetic flux leaking into structural components like the housing and shaft.<\/li>\n\n\n\n<li class=\"gb-text gb-text-b1f80ed0\">Mitigating high windage losses caused by air drag inside the casing at tip speeds approaching 800 km\/h.<\/li>\n\n\n\n<li class=\"gb-text gb-text-abdfe722\">Developing a complex multiphysics design as a startup without the budget for HPC infrastructure or physical prototyping.<\/li>\n<\/div>\n\n\n\n<img loading=\"lazy\" decoding=\"async\" width=\"440\" height=\"440\" class=\"gb-media-463eb495\" alt=\"Emil Motors Challenges\" src=\"https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/emil_motors_challenges_1x.webp\" srcset=\"https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/emil_motors_challenges_1x.webp 440w, https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/emil_motors_challenges_1x-300x300.webp 300w, https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/emil_motors_challenges_1x-150x150.webp 150w\" sizes=\"auto, (max-width: 440px) 100vw, 440px\" \/>\n<\/div>\n\n\n\n<div class=\"gb-element-c52e228f\">\n<div class=\"gb-element-b61859d2\">\n<h2 class=\"gb-text gb-text-c2b0a58f\">Results<\/h2>\n\n\n\n<li class=\"gb-text gb-text-258d3ddc\">Rapidly developed patented cooling system via CHT simulation, keeping coils &lt;100\u00b0C for continuous high torque.<\/li>\n\n\n\n<li class=\"gb-text gb-text-6c0702ac\">Developed robust rotor assembly and validated safe deflection away from stator.<\/li>\n\n\n\n<li class=\"gb-text gb-text-6814c2ae\">Visualized 3D flux leakage to optimize housing geometry and materials, neutralizing parasitic heating effects.<\/li>\n\n\n\n<li class=\"gb-text gb-text-a2f7e26f\">Reduced internal drag by optimizing air gaps through aerodynamic simulation.<\/li>\n\n\n\n<li class=\"gb-text gb-text-e0a64704\">Achieved a ~50% cost reduction compared to conventional simulation and accelerated development time by 2x.<\/li>\n<\/div>\n\n\n\n<img loading=\"lazy\" decoding=\"async\" width=\"440\" height=\"440\" class=\"gb-media-d60be114\" alt=\"Emil Motors Results\" src=\"https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/results_1x-1.webp\" srcset=\"https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/results_1x-1.webp 440w, https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/results_1x-1-300x300.webp 300w, https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/results_1x-1-150x150.webp 150w\" sizes=\"auto, (max-width: 440px) 100vw, 440px\" \/>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n\n\n\n<div class=\"gb-element-3bbef0ea\">\n<div class=\"gb-element-394e24b3\">\n<p class=\"wp-block-paragraph\">The transition to electric mobility faces a critical bottleneck: a reliance on rare earth materials needed to produce permanent magnets for the synchronous radial flux motors found in today\u2019s EVs (electric vehicles). Despite the supply chain volatility and environmental extraction costs, permanent magnets are considered essential to achieve the motor torque and efficiency requirements of a modern EV &#8211; performance that asynchronous radial flux (induction) motors cannot match.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Founded in 2023 and headquartered in Hersbruck, Germany, <a href=\"https:\/\/www.emil-motors.com\/\" target=\"_blank\" rel=\"noreferrer noopener\">Emil Motors<\/a> sees things differently. The company was established with a singular mission: to resolve the EV industry&#8217;s critical dependency on rare earth materials. Their disruptive motor design uses an axial flux configuration to elevate induction motor technology to match the power density of conventional permanent magnet machines.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><a href=\"https:\/\/www.linkedin.com\/in\/maximilian-guettinger-918198169\/\" target=\"_blank\" rel=\"noreferrer noopener\">Maximilian G\u00fcttinger<\/a>, Co-Founder and CEO, drives the company&#8217;s simulation-led engineering strategy. Before founding Emil Motors, he studied mechanical engineering at the Technical University of Munich (TUM). Realizing the sudden shift in the <a href=\"https:\/\/www.simscale.com\/industries\/automotive\/\">automotive market <\/a>and the immediate opportunity for sustainable powertrains, Maximilian and his co-founder <a href=\"https:\/\/www.linkedin.com\/in\/johannes-unhold-b9366b160\/\">Johannes Unhold<\/a> made the bold decision to drop out of university to pursue the venture full-time.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">A Multiphysics Balancing Act<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Emil Motors\u2019 Segmented Axial Flux Asynchronous Motor (SAM) is a sustainable, cost-effective &#8220;drop-in&#8221; replacement for permanent magnet motors. By utilizing a Dual Rotor, Central Stator configuration with an aluminum induction cage, the SAM delivers 330 kW and 450 Nm of torque in a package weighing just 35 kg\u2014all without a single gram of rare earth material.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">To make an induction motor competitive with the best permanent magnet motors, the team had to overcome the inherent thermal, mechanical, and electromagnetic disadvantages of induction technology. As Maximilian explains, \u201cDeveloping a product like this from scratch requires a lot of simulation work across multiple physics to explore all of the possibilities in the design space.\u201d<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Emil Motors needed a professional-grade solution that <a href=\"https:\/\/www.simscale.com\/product\/integrations-partners\/onshape-cad\/\">integrated seamlessly with their CAD workflow in Onshape<\/a>. This led them to SimScale&#8217;s <a href=\"https:\/\/www.simscale.com\/simulations\/electric-motor-design-simulation\/\">electric motor design software <\/a>offering. The platform\u2019s cloud-native architecture allowed the team to import geometry directly from Onshape and run massive parallel simulations across thermal, structural, fluids and electromagnetics domains via a web browser. &#8220;Getting speed, accuracy, usability, and cost efficiency in one package is hard to find anywhere else.&#8221; Maximilian notes, &#8220;Being cloud-based, SimScale makes it easy to get the work done, and the interface and ease of use is better than most of the legacy software out there.\u201d<\/p>\n\n\n\n<div class=\"gb-element-e747b877\">\n<div class=\"gb-element-ecd0b6a0\">\n<div class=\"gb-element-40c01d5c\">\n<img loading=\"lazy\" decoding=\"async\" width=\"200\" height=\"200\" class=\"gb-media-0a7c01bb\" alt=\"Maximilian G\u00fcttinger\" src=\"https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/maximilian_g_ttinger_1x-1.webp\" srcset=\"https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/maximilian_g_ttinger_1x-1.webp 200w, https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/maximilian_g_ttinger_1x-1-150x150.webp 150w\" sizes=\"auto, (max-width: 200px) 100vw, 200px\" \/>\n<\/div>\n\n\n\n<div>\n<p class=\"gb-text gb-text-99881929\">\u201cOne significant advantage of SimScale is the ease of use, especially with Onshape. The CAD can be adapted quickly and ideas can be explored with great detail at an early stage. It takes the legwork out of design exploration and optimization.\u201d<\/p>\n\n\n\n<p class=\"gb-text gb-text-37a06ae3\">Maximilian G\u00fcttinger<\/p>\n\n\n\n<p class=\"gb-text gb-text-a43e3607\">CEO &amp; Co-founder, Emil Motors<\/p>\n<\/div>\n<\/div>\n<\/div>\n\n\n\n<h2 class=\"wp-block-heading\">Thermal Physics: A Patented Direct Oil Cooling System<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Early in development, the team hypothesized that standard external cooling would be insufficient for the amount of Joule heating in the stator, especially with the dual rotor design restricting access. Using <a href=\"https:\/\/www.simscale.com\/product\/thermal-analysis\/\">SimScale\u2019s Conjugate Heat Transfer (CHT) <\/a>capabilities, they developed a radical &#8220;Direct Oil Cooling&#8221; concept. The design features a segmented stator dozens of individual sections, each containing integrated channels where transmission oil flows directly against the insulated copper coils.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The team simulated the 3D fluid dynamics to optimize the hydraulic pressure balance across the different cooling channels to ensure uniform cooling throughout the stator. This process involved navigating many tradeoffs, as Maximilian recalls: \u201cA critical aspect was the sizing of the internal channel through the iron core, allowing fluid to flow from one side of the rotor to the other. A wider channel provides better cooling but reduces the efficiency of the stator core by removing ferrous material.\u201d<\/p>\n\n\n\n<figure class=\"gb-element-44931146\">\n<img loading=\"lazy\" decoding=\"async\" width=\"1200\" height=\"890\" class=\"gb-media-25f63b6f\" alt=\"Streamlines showing oil cooling flow through a pair of stator segments (streamlines colored by Temperature)\" src=\"https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/streamlines_showing_oil_cooling_flow_through_a_pair_of_stator_segments_streamlines_colored_by_temperature__1x-1.webp\" srcset=\"https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/streamlines_showing_oil_cooling_flow_through_a_pair_of_stator_segments_streamlines_colored_by_temperature__1x-1.webp 1200w, https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/streamlines_showing_oil_cooling_flow_through_a_pair_of_stator_segments_streamlines_colored_by_temperature__1x-1-300x223.webp 300w, https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/streamlines_showing_oil_cooling_flow_through_a_pair_of_stator_segments_streamlines_colored_by_temperature__1x-1-1024x759.webp 1024w, https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/streamlines_showing_oil_cooling_flow_through_a_pair_of_stator_segments_streamlines_colored_by_temperature__1x-1-768x570.webp 768w, https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/streamlines_showing_oil_cooling_flow_through_a_pair_of_stator_segments_streamlines_colored_by_temperature__1x-1-515x382.webp 515w\" sizes=\"auto, (max-width: 1200px) 100vw, 1200px\" \/>\n\n\n\n<figcaption class=\"gb-text gb-text-53c216f2\">Streamlines showing oil cooling flow through a pair of stator segments (streamlines colored by Temperature)<\/figcaption>\n<\/figure>\n\n\n\n<p class=\"wp-block-paragraph\">The results were transformative: the simulation predicted the motor could run at 50% of peak torque (approx. 200 Nm) continuously while keeping coil temperatures below 100\u00b0C\u2014a massive 40-degree reduction compared to the industry standard of 140\u00b0C. Physical testing later confirmed these thermal predictions to be within 99% accuracy.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Structural Mechanics: Mastering Rotor Dynamics at 16,000 RPM<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">To compensate for the lack of strong magnetic flux from rare earth magnets, the SAM design must spin faster to generate equivalent power. Reaching the target speed of 16,000 RPM exerts extreme centrifugal forces on the 300 mm diameter rotors and because of the small air gaps needed in axial flux machines, rotor deformation under load has to be very carefully managed.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The team used Finite Element Analysis (FEA) in SimScale to guide the design of the rotor assembly and explore ways to achieve their target operational speed without exceeding the limits of the materials. FEA initially showed stresses in the outer retaining ring exceeding 1,000 MPa, predicting that steel would fail and necessitating a carbon fiber sleeve. By iterating through more than 20 geometries, the team optimized the adhesive bonding strategy between the aluminum and steel to stiffen the structure and control this bending motion.<\/p>\n\n\n\n<figure class=\"gb-element-557b1a16\">\n<img loading=\"lazy\" decoding=\"async\" width=\"1135\" height=\"723\" class=\"gb-media-0af009b2\" alt=\"Stress distribution and rotor distortion at high speed (plot shows Von Mises Stress)\" src=\"https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/stress_distribution_and_rotor_distortion_at_high_speed_plot_shows_von_mises_stress__1x-2.webp\" title=\"stress_distribution_and_rotor_distortion_at_high_speed_plot_shows_von_mises_stress__1x-2\" srcset=\"https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/stress_distribution_and_rotor_distortion_at_high_speed_plot_shows_von_mises_stress__1x-2.webp 1135w, https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/stress_distribution_and_rotor_distortion_at_high_speed_plot_shows_von_mises_stress__1x-2-300x191.webp 300w, https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/stress_distribution_and_rotor_distortion_at_high_speed_plot_shows_von_mises_stress__1x-2-1024x652.webp 1024w, https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/stress_distribution_and_rotor_distortion_at_high_speed_plot_shows_von_mises_stress__1x-2-768x489.webp 768w, https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/stress_distribution_and_rotor_distortion_at_high_speed_plot_shows_von_mises_stress__1x-2-515x328.webp 515w\" sizes=\"auto, (max-width: 1135px) 100vw, 1135px\" \/>\n\n\n\n<figcaption class=\"gb-text gb-text-9a1b5dd9\">Stress distribution and rotor distortion at high speed (plot shows Von Mises Stress)<\/figcaption>\n<\/figure>\n\n\n\n<p class=\"wp-block-paragraph\">FEA simulations also revealed that, due to the mass distribution of the heavy iron core relative to the aluminum spokes, centrifugal forces caused the rotor discs to &#8220;dish&#8221; away from the central stator at high speeds. Maximilian explains, &#8220;This was a very helpful discovery, since it effectively works as a self-governing mechanism to prevent contact between the rotors and stator. It\u2019s a critical consideration with an air gap of only 0.6mm\u201d<\/p>\n\n\n\n<figure class=\"gb-element-acab41bd\">\n<img loading=\"lazy\" decoding=\"async\" width=\"1200\" height=\"328\" class=\"gb-media-3ac9e227\" alt=\"\u201cDishing\u201d effect observed at high speed, causing the rotor to safely deflect away from the stator\" src=\"https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/dishing_effect_observed_at_high_speed_causing_the_rotor_to_safely_deflect_away__1x-1.webp\" title=\"dishing_effect_observed_at_high_speed_causing_the_rotor_to_safely_deflect_away__1x-1\" srcset=\"https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/dishing_effect_observed_at_high_speed_causing_the_rotor_to_safely_deflect_away__1x-1.webp 1200w, https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/dishing_effect_observed_at_high_speed_causing_the_rotor_to_safely_deflect_away__1x-1-300x82.webp 300w, https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/dishing_effect_observed_at_high_speed_causing_the_rotor_to_safely_deflect_away__1x-1-1024x280.webp 1024w, https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/dishing_effect_observed_at_high_speed_causing_the_rotor_to_safely_deflect_away__1x-1-768x210.webp 768w, https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/dishing_effect_observed_at_high_speed_causing_the_rotor_to_safely_deflect_away__1x-1-515x141.webp 515w\" sizes=\"auto, (max-width: 1200px) 100vw, 1200px\" \/>\n\n\n\n<figcaption class=\"gb-text gb-text-dd1de7c7\">\u201cDishing\u201d effect observed at high speed, causing the rotor to safely deflect away from the stator (magnified and colored by Displacement)<\/figcaption>\n<\/figure>\n\n\n\n<h2 class=\"wp-block-heading\">Electromagnetics: Visualizing the Invisible<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">While Emil Motors employs 2D simulation tools for rapid iterative sizing, they rely on <a href=\"https:\/\/www.simscale.com\/product\/electromagnetics-simulation\/\">SimScale to solve complex 3D electromagnetic phenomena<\/a> that are critical to the machine&#8217;s efficiency.&nbsp;<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Optimizing Core Saturation&nbsp;<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">The team utilized 3D &#8220;no-load&#8221; simulations to visualize the magnetic flux distribution within the iron core. This allowed them to precisely size the stator teeth and iron back-iron. If the iron is too thin, the magnetic flux saturates , choking performance. If too thick, the motor becomes heavy and sluggish. By mapping the flux density in 3D, Emil Motors identified the exact material threshold, trimming excess iron to minimize weight without compromising magnetic saturation.<\/p>\n\n\n\n<figure class=\"gb-element-13076fad\">\n<img loading=\"lazy\" decoding=\"async\" width=\"1200\" height=\"724\" class=\"gb-media-fb4de232\" alt=\"Visualizing core saturation in a prototype rotor design (rotor and stator surfaces colored by Magnetic Flux Density)\" src=\"https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/visualizing_core_saturation_in_a_prototype_rotor_design_rotor_and_stator_surfaces_colored_by_magnetic_flux_density__1x.webp\" srcset=\"https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/visualizing_core_saturation_in_a_prototype_rotor_design_rotor_and_stator_surfaces_colored_by_magnetic_flux_density__1x.webp 1200w, https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/visualizing_core_saturation_in_a_prototype_rotor_design_rotor_and_stator_surfaces_colored_by_magnetic_flux_density__1x-300x181.webp 300w, https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/visualizing_core_saturation_in_a_prototype_rotor_design_rotor_and_stator_surfaces_colored_by_magnetic_flux_density__1x-1024x618.webp 1024w, https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/visualizing_core_saturation_in_a_prototype_rotor_design_rotor_and_stator_surfaces_colored_by_magnetic_flux_density__1x-768x463.webp 768w, https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/visualizing_core_saturation_in_a_prototype_rotor_design_rotor_and_stator_surfaces_colored_by_magnetic_flux_density__1x-515x311.webp 515w\" sizes=\"auto, (max-width: 1200px) 100vw, 1200px\" \/>\n\n\n\n<figcaption class=\"gb-text gb-text-d9287189\">Visualizing core saturation in a prototype rotor design (rotor and stator surfaces colored by Magnetic Flux Density)<\/figcaption>\n<\/figure>\n\n\n\n<h3 class=\"wp-block-heading\">Hunting Stray Losses<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">The most critical value of 3D simulation lay in identifying &#8220;stray losses&#8221; &#8211; locations where magnetic fields leak out of the active core and pass through nearby structural components like the housing, the backplate, and the shaft. &#8220;If you make those parts from standard mild steel, they are magnetic,&#8221; Maximilian notes. &#8220;They can actually have a significant effect on the machine.&#8221;<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">When the leaking magnetic field hits these conductive parts, it induces unwanted eddy currents, which generate heat without contributing to torque. Because these components are geometrically complex and sit outside the 2D plane, these losses are invisible in 2D simulations. SimScale\u2019s 3D analysis generated a &#8220;heat map&#8221; of losses, revealing exactly which structural components were absorbing energy. This insight allowed the team to modify the housing geometry, increasing the air gap between magnetic parts and the case, and switch specific components to non-magnetic materials, effectively neutralizing these parasitic losses.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Internal Aerodynamics: Reducing Drag<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Another source of loss to be quantified is aerodynamic drag on the rotors. At 16,000 RPM, the air inside the motor behaves less like a gas and more like a viscous fluid. This creates &#8220;windage loss&#8221;\u2014drag that resists the rotation of the rotor.<\/p>\n\n\n\n<figure class=\"gb-element-dd1f7edb\">\n<img loading=\"lazy\" decoding=\"async\" width=\"1200\" height=\"724\" class=\"gb-media-7b724c5a\" alt=\"Aerodynamic simulation of a rotor (surfaces colored by Pressure, streamlines colored by Velocity Magnitude)\" src=\"https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/aerodynamic_simulation_of_a_rotor_surfaces_colored_by_pressure_streamlines_colored_by_velocity_magnitude__1x-1.webp\" srcset=\"https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/aerodynamic_simulation_of_a_rotor_surfaces_colored_by_pressure_streamlines_colored_by_velocity_magnitude__1x-1.webp 1200w, https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/aerodynamic_simulation_of_a_rotor_surfaces_colored_by_pressure_streamlines_colored_by_velocity_magnitude__1x-1-300x181.webp 300w, https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/aerodynamic_simulation_of_a_rotor_surfaces_colored_by_pressure_streamlines_colored_by_velocity_magnitude__1x-1-1024x618.webp 1024w, https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/aerodynamic_simulation_of_a_rotor_surfaces_colored_by_pressure_streamlines_colored_by_velocity_magnitude__1x-1-768x463.webp 768w, https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/aerodynamic_simulation_of_a_rotor_surfaces_colored_by_pressure_streamlines_colored_by_velocity_magnitude__1x-1-515x311.webp 515w\" sizes=\"auto, (max-width: 1200px) 100vw, 1200px\" \/>\n\n\n\n<figcaption class=\"gb-text gb-text-836faba7\">Aerodynamic simulation of a rotor (surfaces colored by Pressure, streamlines colored by Velocity Magnitude)<\/figcaption>\n<\/figure>\n\n\n\n<p class=\"wp-block-paragraph\">Maximilian performed internal aerodynamic simulations to measure this effect and to understand how to mitigate it. Simulation results showed that a smaller gap between the rotor and outer casing resulted in lower turbulence levels in the annular space, with a corresponding lower drag force on the rotor. This led the design team to minimize the clearance around the rotors as part of the push for overall motor efficiency. As Maximilian notes, \u201cto achieve our goal of matching the efficiency of permanent magnet motors, we look to optimize every aspect of the motor, whether that is in the electromagnetic design, thermal management, mechanical or aerodynamic.\u201d<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Future Outlook<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">The strategic adoption of SimScale allowed Emil Motors to condense years of R&amp;D into a streamlined, cloud-native workflow. By integrating SimScale directly with Onshape, the team achieved a <strong>2x speed up<\/strong> in iteration cycles, moving from CAD to simulation results seamlessly. In October 2025, the company announced the successful hardware validation of its prototype, a milestone that proves the SAM architecture is an industrial reality.<\/p>\n\n\n\n<div class=\"gb-element-019e3443\">\n<div class=\"gb-element-09f3b7db\">\n<div class=\"gb-element-c217448b\">\n<img loading=\"lazy\" decoding=\"async\" width=\"200\" height=\"200\" class=\"gb-media-aa237e5a\" alt=\"Maximilian G\u00fcttinger\" src=\"https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/maximilian_g_ttinger_1x-1.webp\" srcset=\"https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/maximilian_g_ttinger_1x-1.webp 200w, https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/maximilian_g_ttinger_1x-1-150x150.webp 150w\" sizes=\"auto, (max-width: 200px) 100vw, 200px\" \/>\n<\/div>\n\n\n\n<div>\n<p class=\"gb-text gb-text-d0ee6c50\">\u201cIf we didn&#8217;t use simulation to the extent that we&#8217;re using it, we would have to build at least one more full prototype. That would be tens of thousands of euros more. And ultimately, you can&#8217;t improve a design if you don&#8217;t understand the effects that are defining performance.\u201d<\/p>\n\n\n\n<p class=\"gb-text gb-text-35a7b8ff\">Maximilian G\u00fcttinger<\/p>\n\n\n\n<p class=\"gb-text gb-text-155baaa6\">CEO &amp; Co-founder, Emil Motors<\/p>\n<\/div>\n<\/div>\n<\/div>\n\n\n\n<p class=\"wp-block-paragraph\">Looking ahead, Emil Motors is using these validated simulation models to push the design from its current 12,000 RPM test limits toward the ultimate 16,000 RPM target. By solving thermal, structural, and electromagnetic challenges in parallel, they have engineered a motor that can break the industry\u2019s dependence on rare earth materials, securing a more sustainable future for the electric vehicle industry.<\/p>\n<\/div>\n<\/div>\n\n\n\n<div class=\"gb-element-f5bbb12e\">\n<div class=\"gb-element-5864c4e7\">\n<h2 class=\"gb-text gb-text-aea88abd\">See more success stories<\/h2>\n\n\n\n<div class=\"gb-element-e9de5332\">\n<div class=\"gb-element-2b7fc583\">\n<div class=\"gb-query-106e68be\"><div class=\"gb-looper-0f37d9ea\">\n<div class=\"gb-loop-item gb-loop-item-16c8c182 post-109004 page type-page status-publish has-post-thumbnail hentry\">\n<div class=\"gb-element-c17136d1\" style=\"--inline-bg-image: url(https:\/\/frontend-assets.simscale.com\/media\/2025\/12\/emil_motors_cover_image_1x.webp)\"><\/div>\n\n\n\n<div class=\"gb-element-7304e23b\">\n<h3 class=\"gb-text gb-text-51af4ee5\"><a href=\"https:\/\/www.simscale.com\/customers\/emil-motors-high-performance-ev-drives\/\">Emil Motors &#8211; High-Performance EV Drives<\/a><\/h3>\n<\/div>\n\n\n<\/div>\n<\/div><\/div>\n<\/div>\n\n\n\n<div class=\"gb-element-6adf9a09\">\n<div class=\"gb-query-1cb0e871\"><div class=\"gb-looper-85b9d10e\">\n<div class=\"gb-loop-item gb-loop-item-885dbe25 post-98521 page type-page status-publish has-post-thumbnail hentry\">\n<div class=\"gb-element-23365c0c\" style=\"--inline-bg-image: url(https:\/\/frontend-assets.simscale.com\/media\/2024\/12\/griffon-feature.webp)\"><\/div>\n\n\n\n<div class=\"gb-element-59ea556b\">\n<h3 class=\"gb-text gb-text-989851e3\"><a href=\"https:\/\/www.simscale.com\/customers\/griffon-hovercraft-design-for-challenging-marine-environments\/\">Griffon Hovercraft Design for Challenging Marine Environments<\/a><\/h3>\n<\/div>\n\n\n<\/div>\n<\/div><\/div>\n<\/div>\n\n\n\n<div class=\"gb-element-d4bc636e\">\n<div class=\"gb-query-8e105707\"><div class=\"gb-looper-c4d5339b\">\n<div class=\"gb-loop-item gb-loop-item-918bd619 post-89255 page type-page status-publish has-post-thumbnail hentry\">\n<div class=\"gb-element-8869c43b\" style=\"--inline-bg-image: url(https:\/\/frontend-assets.simscale.com\/media\/2024\/02\/202402-Energyminer-Feature.webp)\"><\/div>\n\n\n\n<div class=\"gb-element-ae9c1ef8\">\n<h3 class=\"gb-text gb-text-a517e5f1\"><a href=\"https:\/\/www.simscale.com\/customers\/energyminer-optimizes-micro-hydropower-plant\/\">Energyminer Optimizes Its Micro-Hydropower Plant with SimScale<\/a><\/h3>\n<\/div>\n\n\n<\/div>\n<\/div><\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n\n\n\n<div class=\"gb-element-d1d43188\">\n<div class=\"gb-element-4a89bab3\">\n<p class=\"gb-text gb-text-ed944d06 p\">Set up your own cloud-native simulation via the web in minutes by creating an account on the SimScale platform. No installation, special hardware, or credit card is required.<\/p>\n\n\n\n<div class=\"gb-element-ac7061bc\">\n<div>\n<a class=\"gb-text gb-text-830cabc9\" href=\"\/signup\/\">Start Simulating<\/a>\n<\/div>\n\n\n\n<div class=\"gb-element-3a131f83\">\n<a class=\"gb-text gb-text-4b971913\" href=\"\/request-demo\/\">Request Demo<\/a>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n","protected":false},"excerpt":{"rendered":"<p>Emil Motors &#8211; Engineering a Magnet-Free Future for High-Performance EV Drives 50% cost saving over legacy tools...","protected":false},"author":195,"featured_media":109024,"parent":8006,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"templates\/template-individual-customer-page2.php","meta":{"_acf_changed":false,"_crdt_document":"","inline_featured_image":false,"footnotes":""},"class_list":["post-109004","page","type-page","status-publish","has-post-thumbnail","hentry"],"acf":[],"_links":{"self":[{"href":"https:\/\/www.simscale.com\/wp-json\/wp\/v2\/pages\/109004","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.simscale.com\/wp-json\/wp\/v2\/pages"}],"about":[{"href":"https:\/\/www.simscale.com\/wp-json\/wp\/v2\/types\/page"}],"author":[{"embeddable":true,"href":"https:\/\/www.simscale.com\/wp-json\/wp\/v2\/users\/195"}],"replies":[{"embeddable":true,"href":"https:\/\/www.simscale.com\/wp-json\/wp\/v2\/comments?post=109004"}],"version-history":[{"count":0,"href":"https:\/\/www.simscale.com\/wp-json\/wp\/v2\/pages\/109004\/revisions"}],"up":[{"embeddable":true,"href":"https:\/\/www.simscale.com\/wp-json\/wp\/v2\/pages\/8006"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.simscale.com\/wp-json\/wp\/v2\/media\/109024"}],"wp:attachment":[{"href":"https:\/\/www.simscale.com\/wp-json\/wp\/v2\/media?parent=109004"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}