Electric Mobility: Mercedes-Benz Demonstrates Technological Lead in Axial-Flux Electric Motors
Berlin-Marienfelde, Germany – Mercedes-Benz is setting new benchmarks for electric vehicle powertrains at its German production base. At its Berlin-Marienfelde plant, Mercedes-Benz Group AG has started large-scale series production of a new axial-flux electric motor. The long-established site is thereby becoming the group’s competence centre for high-performance electric motors.
Highly Automated Production with Significant Innovation Content
Until now, axial-flux motors have primarily been manufactured for prototypes and low-volume production runs. With the start of production in Berlin-Marienfelde, Mercedes-Benz is now bringing the technology into industrial-scale series manufacturing.
Production of the axial-flux motor comprises a total of 98 process steps. Of these, 65 are being used for the first time within the group and 35 for the first time worldwide. According to Mercedes-Benz, the development of the manufacturing technologies has resulted in more than 30 patent applications.
Across approximately 30,000 square metres of production space, spanning three halls and seven production lines, the company combines automated manufacturing, laser technology, AI-supported quality control and high-precision control systems.
One of the key challenges is the production of the stator copper coils. The process uses rectangular copper wire that must be formed into tight radii at high speed without damaging the insulation. The manufacturing process was newly developed in cooperation with industry partners.
Precision Assembly Under High Magnetic Forces
During final assembly, known internally as the “marriage” process, the stator is inserted between two magnetic rotor discs and fixed in place. Forces of up to 9 kN, equivalent to approximately 900 kilograms, act on the components during this stage. Positioning accuracy is maintained within a tolerance of less than 0.1 millimetres, with a dedicated control algorithm actively making adjustments during the final assembly phase.
“With the start of large-scale series production of the axial-flux motor in Berlin-Marienfelde, we are bringing a pioneering innovation in electromobility into industrial reality. This sends a strong signal for technological leadership, operational excellence and the transformation of Germany’s automotive industry,” said Michael Schiebe, Member of the Board of Management responsible for Production, Quality and Supply Chain Management at Mercedes-Benz Group AG.
German Transport Minister Patrick Schnieder described the launch as a positive signal for Germany as an industrial location and referred to the federal government's Charging Infrastructure Master Plan 2030 as a key element in supporting electromobility.
About Axial-Flux Technology: Compact and High-Performance
Conventional electric vehicles typically use so-called radial-flux motors. In a radial-flux motor, the rotor and stator are arranged concentrically in a cylindrical configuration, similar to two nested tubes. The rotor is the rotating component, while the stator remains stationary. The magnetic flux runs radially to the drive axis.
The new Mercedes-Benz motors, by contrast, are based on the axial-flux principle. The rotor remains the rotating component while the stator is stationary. Both components are arranged as flat discs facing each other, comparable to a turntable: the record (rotor) rotates while the pickup arm (stator) remains fixed above it. In this configuration, the magnetic flux runs parallel to the drive axis.
The result is high power and torque density in a compact design, providing advantages in terms of installation space, weight and vehicle range.
The technology is based on developments by the UK-based company YASA Limited and has previously been used in high-performance vehicles. Mercedes-Benz Group AG is now bringing what was previously a low-volume production technology into industrial-scale manufacturing for the first time.
The key achievement lies in scaling the manufacturing processes to series-production levels and thereby industrialising a drive technology that has until now remained highly specialised.
Source: IWR Online, 15 Jun 2026
