A Magnet-Free EV Motor: How Robert Sansone Is Pioneering Greener Electric Vehicles
A teenager's breakthrough in magnet-free electric motors could make EVs greener by eliminating reliance on rare-earth metals.
Robert Sansone: The Young Visionary Behind Greener Motors
At just 17 years old, Robert Sansone has sparked international attention by reinventing the electric motor—a component at the heart of the ongoing green transportation revolution. His creation, a prototype magnet-free synchronous reluctance motor, aims to solve pressing environmental and economic issues in electric vehicle (EV) manufacturing by eliminating the need for rare-earth metals.
Sansone’s journey exemplifies youthful innovation, determination, and a commitment to sustainable engineering. Working with limited resources from his home in Fort Pierce, Florida, he has developed a solution that could ultimately transform the way electric vehicles are powered worldwide.
Rare-Earth Metals: The Hidden Problem in Today’s EVs
While EVs are increasingly hailed as a critical step toward a cleaner future, their production often relies on rare-earth metals such as neodymium, dysprosium, and samarium. These metals are essential in the construction of powerful permanent magnets for modern electric motors, including those found in many leading EV models.
- Environmental impact: Mining and processing rare-earth metals devastate ecosystems, emit hazardous chemicals, and cause significant CO2 emissions.
- Supply chain risk: Most rare-earth reserves are concentrated in a few regions—primarily China—raising concerns of supply bottlenecks and geopolitical vulnerabilities.
- High costs: Manufacturers face skyrocketing prices for these metals, potentially making green transport less accessible and affordable.
In search of alternatives, engineers have explored various rare-earth-free motor types. However, most struggle to match the performance and efficiency of rare-earth magnet-based designs—until Sansone’s breakthrough offered new hope.
Understanding Synchronous Reluctance Motors: A Foundation Reimagined
Sansone’s invention builds on an established, eco-friendly motor type: the synchronous reluctance motor (SynRM). SynRMs operate using steel rotors and do not require any magnets, let alone those made from rare-earth elements. Traditionally, these motors are found in lower-power applications—such as fans and pumps—because they can’t generate the torque and efficiency needed for EV propulsion.
But what if that limitation could be overcome? Sansone set out to tackle this exact challenge, driven by a desire to make electrified mobility fully sustainable from production through operation.
How Sansone’s Novel Motor Design Works
The key to his design lies in boosting the “saliency ratio”—a measure of how effectively the motor’s steel rotor channels magnetic lines of force. In technical terms, the higher the saliency ratio, the more torque and efficiency a synchronous reluctance motor can achieve.
- Traditional SynRM limitations: They depend on air gaps in steel rotors, leading to relatively low performance compared to magnet-based designs.
- Sansone’s innovation: His prototype incorporated a revised magnetic geometry, introducing a supplementary magnetic field to amplify the saliency ratio. This means the motor can deliver more power with less energy loss, opening the possibility of use in demanding EV applications.
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The Engineering Journey: From Idea to Prototype
- Sansone built 15 prototypes using 3D-printed plastic, copper wire, and steel rotors—without the benefits of laboratory funding or formal mentoring.
- Countless hours were spent troubleshooting issues, iteratively refining the design and the materials for optimum performance.
- Key hurdles included material limitations (like melting plastics at high RPMs) and the need to validate theoretical improvements with hands-on measurement.
- Eventually, Sansone’s perseverance paid off with a working prototype that exceeded expectations.
As Robert Sansone himself describes, “Seeing the day when EVs are fully sustainable due to the help of my novel motor design would be a dream come true.”
Impressive Test Results: How Does the Motor Perform?
Sansone’s prototype was rigorously tested and benchmarked against existing synchronous reluctance motors. The results were extraordinary, particularly considering the absence of rare-earth magnets and the limitations of the prototype’s materials.
| Parameter | Traditional SynRM | Sansone’s Design | Improvement (%) |
|---|---|---|---|
| Torque (at 300 RPM) | Baseline | 39% higher | +39% |
| Efficiency (at 300 RPM) | Baseline | 31% higher | +31% |
| Efficiency (at 750 RPM) | Baseline | 37% higher | +37% |
While these tests were conducted at moderate speeds—limited by the durability of 3D-printed parts—the data conclusively showed that the higher saliency ratio directly improved both motor torque and efficiency. Notably, as the motor speed increased, efficiency gains also increased, which is highly desirable for automotive applications.
Why Magnet-Free Motors Matter for a Greener Tomorrow
- Cost Savings: Removing rare-earth magnets from EV motors could dramatically lower manufacturing costs, helping to make EVs more affordable for the average consumer.
- Supply Security: Sourcing common metals like steel and copper is more straightforward than competing for finite rare-earth resources, making the EV supply chain more resilient.
- Environmental Benefits: Avoiding rare-earth mining translates to cleaner production, fewer environmental hazards, and a more sustainable lifecycle for green vehicles.
- Scalability: If manufacturing hurdles can be overcome, this type of motor could be produced at scale worldwide, supporting the mass adoption of clean mobility.
The Roadblocks: Manufacturing Challenges and Future Outlook
Despite the promise, mainstream adoption of magnet-free high-performance motors faces non-trivial engineering and commercial barriers:
- Manufacturing complexity: Producing precision steel rotors with intricate magnetic pathways is complicated and has traditionally kept SynRM costs high relative to performance.
- Material limitations: Sansone’s prototypes depended on affordable materials and 3D printing technology, which cannot withstand the extreme RPMs of real-world EV motors. Further material development and industrial processes are required.
- Validation at scale: The prototype outperformed at lower trial speeds, but needs to be built and tested with high-performance, heat-resistant materials at automotive power levels to verify commercial readiness.
- Technology transfer: Bridging the gap from science fair success to industry product will require collaboration with universities, manufacturers, and significant financial investment.
Experts like Professor Heath Hofmann (University of Michigan) acknowledge the ingenuity and potential of Sansone’s work, even as they note the need for scalable manufacturing process innovation in the future.
The Awards and Recognition: From Science Fair to National Headlines
Sansone’s project earned broad acclaim, culminating in first place at the 2022 Regeneron International Science and Engineering Fair (ISEF)—the world’s most prestigious high school science competition. With this accomplishment, he claimed a $75,000 prize, further igniting media coverage and interest in his pioneering work.
- This was just one highlight in a portfolio of 60+ independent engineering projects, showcasing Sansone’s rare blend of creativity and technical rigor.
- He is now considering future steps including advanced university study (with aspirations for MIT) and further research to mature the motor technology.
As word spreads, the industry and environmental advocates alike have recognized the potential of his design to help decouple the future of EVs from unsustainable materials.
Technology’s Broader Impact: Teen Innovators Driving the Sustainability Revolution
The progress achieved by Robert Sansone underscores a larger theme: groundbreaking sustainability innovations are not limited to established corporations or academic powerhouses. Often, they emerge from the fresh thinking and determination of young inventors. His motor offers hope for:
- Accelerating the pace of green mobility by lowering both environmental and economic barriers.
- Inspiring a new wave of student engineers to tackle global challenges head-on.
- Demonstrating the transformative role of STEM education and hands-on experimentation.
As Sansone himself says, “If my work could play even a small part in making EVs truly sustainable, it would feel like I’ve contributed to the future.”
Frequently Asked Questions (FAQs)
What is a synchronous reluctance motor?
A synchronous reluctance motor is an electric motor that operates using a steel rotor and does not require permanent magnets—especially not those made of rare-earth metals. Instead, it uses differences in magnetic reluctance within the rotor to generate torque.
How does Sansone’s motor differ from traditional EV motors?
While most conventional EV motors use strong rare-earth magnets for high torque and efficiency, Sansone’s design boosts the efficiency of a magnet-free synchronous reluctance motor by enhancing the motor’s saliency ratio, enabling it to achieve similar or superior performance in lab tests, without the environmental or supply drawbacks.
Why are rare-earth metals problematic for EVs?
Rare-earth metals are expensive, environmentally damaging to mine and refine, and subject to monopolistic supply chains that threaten both cost stability and scalability for global EV markets.
What are the next steps before this motor can be used in real cars?
The prototype must be scaled up using industrial-grade, heat-resistant materials, proven at higher RPMs and torques, and produced via manufacturing processes compatible with automotive industry standards.
How did Sansone validate his results?
By constructing multiple design iterations and using rigorous measurement tools, including laser tachometers and electrical meters, Sansone eliminated variables and confirmed the role of his enhanced magnetic geometry in achieving higher torque and efficiency.
Conclusion: The Road Ahead for Sustainable EV Motors
Robert Sansone’s magnet-free motor exemplifies ingenuity and sustainable innovation. If the technical and manufacturing barriers can be overcome, this breakthrough could make electric vehicles not just cleaner to operate, but truly green from the ground up—setting new benchmarks for what’s possible when science, passion, and purpose align.
References
- https://www.ediweekly.com/report-17-year-old-student-invents-innovative-new-electric-motor-that-could-transform-the-ev-industry/
- https://www.powerelectronicsnews.com/prototype-magnet-free-ev-motor-could-transform-engine-design/
- https://mymodernmet.com/robert-sansone-ev-motor/
- https://www.youtube.com/watch?v=l52eT5BJ6Fo
- https://www.smithsonianmag.com/innovation/this-17-year-old-designed-a-motor-that-could-potentially-transform-the-electric-car-industry-180980550/
- https://www.youtube.com/watch?v=TYGdpJfpa3k
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