Mercedes-Benz Pioneers the Future of E-Mobility: Serial Production of Axial-Flux Motors Begins in Berlin

In a landmark development for the automotive industry, Mercedes-Benz has officially inaugurated the large-scale production of its revolutionary axial-flux electric motors at the historic Berlin-Marienfelde plant. This move marks a pivotal shift in the company’s electrification strategy, transforming a factory with over a century of automotive heritage into a state-of-the-art hub for high-performance electric drive technology. The new motor, which powers the high-performance Mercedes-AMG GT 4-Door Coupé, is being hailed as the "V8 of the electric era," promising a blend of extreme power density and compact design that could redefine the standards of electric propulsion.

The Genesis of the "Pancake" Motor

The axial-flux motor represents a radical departure from the conventional radial-flux motors found in the vast majority of today’s electric vehicles. While radial motors feature a cylindrical rotor that spins inside a stator, the axial-flux design—often referred to as a "pancake" motor due to its disc-shaped profile—arranges the magnetic field parallel to the motor’s axis.

In this configuration, two rotors sandwich a central stator. This geometry allows for significantly shorter flux paths and a more efficient utilization of magnetic fields. For Mercedes-Benz, the benefits are clear: the motor occupies less than a third of the space of a traditional unit, weighs only a fraction as much, yet delivers triple the power density. This breakthrough is the result of years of research and the strategic 2021 acquisition of Yasa, a British specialist in axial-flux technology, which has since been integrated as a wholly-owned subsidiary of the Mercedes-Benz Group.

Chronology: From Concept to Berlin Production

The journey toward this industrial milestone has been one of rapid innovation and intense development:

• 2021: Mercedes-Benz acquires Yasa, signaling its intent to dominate the high-performance electric segment.
• 2022–2023: Intensive development of the prototype technology, focusing on scaling the motor for automotive production standards.
• 2024: The "Concept AMG GT XX" serves as the primary testbed for the technology, undergoing rigorous durability testing at the Nardò Technical Center in Italy.
• Mid-2026: The transformation of the Berlin-Marienfelde plant is completed, with the facility officially designated as a competence center for high-performance electric drives.
• Late 2026: The official start of serial production for the Mercedes-AMG GT 4-Door Coupé, marked by the presence of federal officials, including German Transport Minister Patrick Schnieder.

Engineering Excellence: Performance Data and Capabilities

The performance metrics associated with the new drive unit are nothing short of extraordinary. The motor is capable of achieving rotational speeds exceeding 15,000 revolutions per minute (RPM). In the Mercedes-AMG GT 4-Door Coupé, these motors are integrated into High Performance Electric Drive Units (HP.EDU), which combine the motor with a compact single-speed planetary gearbox.

Extreme Durability

During the Nardò endurance trials, the technology demonstrated its resilience. A prototype vehicle completed over 40,000 kilometers in just seven days and 13 hours, setting 25 long-distance records. Even in grueling conditions—with ambient temperatures reaching 35°C—the vehicle maintained a constant speed of 300 km/h, supported by an 850 kW fast-charging infrastructure.

Key to this success is the advanced cooling system. Unlike standard electric motors where heat dissipation from copper coils is a major bottleneck, the Yasa-designed motor utilizes a non-conductive liquid that flows directly over the coils. This enables sustained high-performance output without the typical power degradation associated with overheating.

Official Perspectives and Strategic Implications

The inauguration in Berlin is more than just a production start; it is a statement of intent. By choosing Marienfelde—a site that has built internal combustion engines since 1902—Mercedes-Benz is sending a strong signal about the transition of the German automotive workforce.

"This is the V8 of the electric age," noted company spokespeople during the launch ceremony. The implication is that performance, torque, and emotional driving dynamics are not casualties of the shift to electricity, but rather variables that can be optimized through superior engineering. Michael Schiebe, now the Production Board Member of the Mercedes-Benz Group, emphasized that the technology ensures "enormous performance and extremely fast charging are permanently available," addressing two of the primary pain points in current EV adoption.

The Production Challenge: A New Industrial Paradigm

The manufacturing process for the axial-flux motor is perhaps as impressive as the motor itself. Because of its unique geometry, standard automotive production lines could not be repurposed; entirely new processes had to be developed.

Precision Engineering of Copper Coils

One of the most complex tasks involves the winding of the stator coils. Engineers transitioned to rectangular copper wire to maximize copper density within the motor’s limited volume. However, bending this wire into tight radii without creating wrinkles, damaging the insulation, or reducing the cross-section required the invention of entirely new industrial bending techniques.

Laser-Welded Connectivity

Connecting the spools in a confined space presented another hurdle. Traditional soldering was deemed insufficient due to the risk of heat damage to surrounding plastic structures. The solution was the development of high-precision laser-welding technology. This process minimizes energy input, ensuring that connections are robust and reliable while keeping the thermal footprint negligible.

The "Wedding" of Components

Perhaps the most difficult phase is the final assembly, or "wedding." The stator must be positioned between two rotors while overcoming magnetic forces of up to 9 kN (approximately 900 kg). Achieving this with a tolerance of less than 0.1 mm requires a sophisticated control algorithm that makes micro-adjustments in the final 0.5 seconds of the process.

The scope of this achievement is underscored by the numbers: 98 distinct process steps are required, 65 of which were used for the first time by Mercedes-Benz, and 35 of which are completely new to the global automotive industry. This technical complexity has resulted in over 30 new patent applications, securing a significant intellectual property advantage for the Stuttgart-based automaker.

Implications for the Future of the Automotive Market

The mass production of axial-flux motors has profound implications for the wider market:

1. Setting the New Benchmark: Mercedes-Benz is moving away from the "one-size-fits-all" approach to electric motors. By utilizing different motor architectures for different vehicle segments, they are creating a performance hierarchy that keeps the brand competitive in the luxury and sports sectors.
2. Sustainability and Efficiency: The increased power density means fewer raw materials (like magnets and copper) are required to achieve the same or better performance than current electric vehicles, aligning with long-term sustainability goals.
3. Industrial Sovereignty: By internalizing the production of these high-tech components, Mercedes-Benz reduces its reliance on third-party suppliers, ensuring greater control over the quality, supply chain, and future iterations of the technology.
4. The Workforce Transition: The success of the Marienfelde plant demonstrates that legacy manufacturing sites can be successfully transitioned to the electric age, provided there is a willingness to invest in radical re-skilling and new manufacturing methodologies.

As the industry watches, the success of the axial-flux motor in the Mercedes-AMG line will likely dictate how quickly this technology permeates down to more mainstream models. For now, Mercedes-Benz has successfully bridged the gap between the raw, visceral power of the internal combustion era and the high-efficiency, high-performance future of the electric age, proving that the heart of the automobile is not dying—it is simply evolving.