Mercedes-Benz has begun large-scale production of its electric axial flux motor at the Berlin-Marienfelde plant, a manufacturing program comprising 98 process steps — 35 of them new worldwide — that has generated more than 30 patent applications. The compact high-performance motor makes its production-vehicle debut in the new Mercedes-AMG GT 4-Door Coupe, according to Mercedes-Benz. The company reports the program establishes its oldest manufacturing site, founded in 1902, as a center of excellence for high-performance electric motors.
Highlights
- Manufacturing comprises 98 process steps; 65 are first-time processes for Mercedes-Benz, and 35 are new worldwide, resulting in more than 30 patent applications.
- Production spans roughly 323,000 square feet (30,000 square meters) across three halls and seven production lines.
- The motor debuts in the all-electric Mercedes-AMG GT 4-Door Coupe, which the company says accelerates from 0 to 62 mph (100 km/h) in as little as 2.1 seconds with peak output of 860 kW (1,169 hp).
- Mercedes-Benz reports a three-digit million-euro investment in transforming the site, which employs around 1,800 people.
How Is the Axial Flux Motor Manufactured?
The motor’s compact design and high power density required manufacturing methods developed specifically for this application. One example is the copper coils: rectangular copper wire in the stator packs more copper into the same installation space than round wire, but it must be bent at high speed into tight radii without creasing, damaging insulation, or reducing the cross-section. Mercedes-Benz says it developed a dedicated process with partners to combine that precision with industrial cycle times.
Joining the coil packages is equally demanding. Each coil end connects to its interconnection wire within a confined space using a highly precise laser weld that minimizes energy input at the welding point. A related process, simultaneous laser transmission welding of plastic drivetrain components, relies on AI-based image processing that detects component position, places virtual protection zones over sensitive areas, and confines the laser to intended surfaces. The company reports the joined components are oil-pressure-tight and withstand high mechanical loads.
Final assembly — known internally as the “wedding” — positions the stator between two magnet-fitted rotor discs. Magnetic forces of up to 9 kN, equivalent to roughly 2,000 pounds (around 900 kilograms), act on the components while the stator must hold the magnetic center plane within a tolerance of less than 0.004 inches (0.1 millimeters). A control algorithm corrects the position in the final 0.5 seconds using high-frequency control impulses.
“With the start of large‑scale series production of the axial flux motor in Berlin‑Marienfelde, we are bringing a pioneering innovation for electromobility into industrial reality. In doing so, we are sending a strong signal of technological leadership, operational excellence and the transformation of the automotive industry in Germany. My special thanks go to the team that made this highly technical and complex project possible with passion, precision, and great pioneering spirit,” said Michael Schiebe, Member of the Board of Management of Mercedes-Benz Group AG, responsible for Production, Quality & Supply Chain Management.
How Does an Axial Flux Motor Differ From a Radial Design?
In an axial flux motor, the electromagnetic flux runs parallel to the axis of rotation rather than perpendicular to it. Two rotors sandwich the stator in a disc-shaped layout the company calls the H-layout, reducing motor length to around one third of a comparable radial flux design while delivering high power and torque density.
The technology traces to British electric motor specialist YASA, which developed the prototype the current motor is based on and has been a wholly owned Mercedes-Benz subsidiary since 2021. The Mercedes-AMG GT 4-Door Coupe uses three of the motors, integrated per axle with a compact planetary gear set into High Performance Electric Drive Units (HP.EDU).
| Position | Width | Maximum speed |
|---|---|---|
| Front axle (one motor) | Just under 3.5 in (9 cm) | More than 15,000 rpm |
| Rear axle (two motors) | About 3.1 in (8 cm) each | More than 13,000 rpm |
The company says the GT 4-Door Coupe reaches a top speed of 186 mph (300 km/h) with the Driver’s Package. Last year, the CONCEPT AMG GT XX technology demonstrator covered more than 24,855 miles (40,000 kilometers) over seven days and 13 hours at Nardò, setting 25 long-distance records.
Berlin-Marienfelde as a Production Innovation Hub
The production launch is tied to the strategic development of the site, which has been part of the global Mercedes-Benz powertrain production network for decades. Since 2022, Berlin-Marienfelde has housed the Mercedes-Benz Digital Factory Campus, a real-world production environment for developing and testing digital applications based on the MO360 production ecosystem. With the axial flux motor’s industrialization, the plant combines high-performance electric drives, digital production, and intelligent automation — supported by what the company describes as extensive qualification and training programs for new highly skilled job profiles.
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