The "V8 of the Electric Era": Mercedes-Benz Launches Serial Production of Revolutionary Axial Flux Motors in Berlin

In a milestone event that signals a paradigm shift for high-performance electric mobility, Mercedes-Benz has officially inaugurated the large-scale production of its cutting-edge axial flux electric motors at its historic Berlin-Marienfelde plant. This facility, which has been at the heart of the company’s powertrain engineering since 1902, is being transformed into a global center of excellence for high-performance electric drive systems.

The launch of this production line marks the world premiere of the axial flux technology in a series-production vehicle: the new Mercedes-AMG GT 4-Door Coupé. The event was attended by high-ranking officials, including Federal Minister of Transport Patrick Schnieder, underscoring the strategic importance of this technological leap for the German automotive industry.

The Technological Leap: Why Axial Flux?

For decades, the internal combustion engine—specifically the V8—defined the automotive gold standard through its combination of immense power, spontaneous torque, and high-revving characteristics. Mercedes-Benz explicitly refers to the new axial flux motor as the "V8 of the electric age," a moniker earned through its radical performance density.

Unlike the traditional radial flux motor, where the electromagnetic flux runs perpendicular to the axis of rotation, the axial flux design directs the flux parallel to the motor’s drive shaft. This fundamental change in geometry allows the motor to take on a "pancake" shape, drastically reducing its physical footprint.

Comparative Performance Metrics

Compared to conventional radial flux motors, the axial flux architecture offers:

• Size: A reduction in installation space to less than one-third of a standard motor.
• Weight: A weight reduction of approximately two-thirds.
• Output: A threefold increase in power density.

This design enables a shorter magnetic flux path, leading to significantly higher efficiency in magnetic field utilization. For the driver, this translates into immediate, brutal acceleration and superior handling dynamics, as the compact units can be integrated closer to the wheels or directly into specialized drive units.

Chronology: From British Innovation to German Serial Production

The journey of this technology is a testament to global collaboration and aggressive R&D.

• 2021: Mercedes-Benz acquires Yasa, a British electric motor specialist based in Oxford, which had pioneered the axial flux motor concept.
• 2022–2023: Intensive development phases occur in Stuttgart and Oxford, focusing on scaling the delicate technology for automotive mass production.
• 2024–2025: Mercedes-Benz commits to retooling the Berlin-Marienfelde site. The factory, once a stronghold of combustion engine component production, undergoes a radical transition to house high-tech assembly lines for electric drive units (HP.EDU).
• June 2026: The official start of serial production. The technology debuts in the Mercedes-AMG GT 4-Door Coupé, following rigorous testing cycles that included the record-breaking Nardò track sessions.

Supporting Data: Testing the Limits of Endurance

The performance potential of the axial flux motor was not merely theorized; it was proven in extreme conditions. The "Concept AMG GT XX" served as the primary technology demonstrator, undergoing a brutal test cycle in Nardò, Italy.

During this trial, the vehicle covered more than 40,000 kilometers in just seven days and 13 hours, setting 25 long-distance records. Most notably, the car completed a 10,000-km run in 44 hours, maintaining a constant speed of 300 km/h. Despite ambient temperatures reaching 35°C and frequent high-speed charging sessions at 850 kW, the powertrain demonstrated zero performance degradation. This level of sustained output is the primary advantage of the axial flux design.

The Role of Advanced Cooling

The secret to this endurance is direct cooling. In a conventional radial motor, heat builds up in the copper windings and is difficult to extract, eventually leading to "thermal throttling" where power drops to prevent damage. In the Yasa-designed axial motor, a non-conductive fluid directly bathes the copper windings, allowing heat to be dissipated at the source. This ensures that the vehicle can sustain peak performance during track days or high-speed autobahn stints without the characteristic power fade seen in earlier EV generations.

Implications for Manufacturing: A New Industrial Era

The transition to mass-producing axial flux motors presented a monumental challenge for Mercedes-Benz’s engineering teams. The assembly process is defined by its extreme precision, requiring 98 distinct steps—65 of which are new to Mercedes-Benz, and 35 of which are completely new to the automotive industry globally.

Precision Engineering Challenges

1. Rectangular Copper Winding: To maximize copper density in the stator, engineers use rectangular rather than round wire. Bending this wire into tight radii at high speeds without damaging the insulation or reducing the cross-section required the invention of entirely new forming processes.
2. Laser-Welded Interconnects: With limited space, the connection of coil ends is performed via high-precision lasers. This method allows for a minimal energy footprint, preventing thermal damage to the surrounding delicate plastic structures.
3. The "Wedding" Process: The assembly of the stator between two rotor discs is the most complex phase. Magnetic forces of up to 9 kN (approx. 900 kg) pull the components together, yet the stator must be positioned within the magnetic center with a tolerance of less than 0.1 mm. A proprietary algorithm uses high-frequency pulse corrections in the final 0.5 seconds of the assembly to ensure perfect alignment.

AI-Driven Quality Assurance

The manufacturing line is integrated with AI-supported optical quality control. Real-time image processing identifies the exact position of components, creates virtual protective zones, and documents every connection. This ensures that even the most complex processes remain robust, repeatable, and compliant with Mercedes-Benz’s stringent quality standards. The project has already resulted in over 30 new patent applications, securing the company’s intellectual property lead in the EV sector.

Official Responses and Strategic Vision

During the opening ceremony, Michael Schiebe, currently the Production Board Member of the Mercedes-Benz Group and former head of AMG, reflected on the significance of the achievement. "The ability to produce this motor at scale is a watershed moment. We are not just building a new motor; we are building a new production philosophy. Enormous performance, combined with rapid charging and extreme reliability, is now a standard, not just a promise."

The choice of Berlin-Marienfelde as the production hub is also symbolic. By repurposing a site that has been operational for over 120 years, Mercedes-Benz is sending a clear message about the future of the German workforce: the transition to electric mobility is not an end to traditional engineering, but an evolution of it.

Looking Ahead: The Future of High-Performance EVs

The integration of these "Pancake" motors into the AMG GT 4-Door Coupé is only the beginning. As the production processes in Berlin-Marienfelde reach full maturity, the scalability of this technology suggests that axial flux motors could eventually migrate into broader vehicle segments, potentially offering smaller, lighter, and more efficient drive options for the entire Mercedes-EQ lineup.

Furthermore, the focus on "High Performance Electric Drive Units" (HP.EDU) highlights a shift toward modularity. By combining the axial motor with compact, single-speed planetary gearsets, Mercedes-Benz is creating a versatile architecture that can be scaled for various performance profiles.

As the industry grapples with the weight and cooling challenges of current electric vehicle designs, Mercedes-Benz has provided a clear, high-performance answer. The axial flux motor represents the convergence of material science, advanced robotics, and traditional German manufacturing precision, effectively setting a new benchmark for what is possible in the electric era. The "Pancake" has arrived, and it is poised to change the face of automotive performance forever.