Electric cars don't just need lighter batteries

Jon Bentley knows that EVs are the heaviest cars on the road, but is hopeful that technological remedies can also help in other ways

- Jon Bentley

It’s common knowledge that electric cars have a weight problem. On average they’re around 30% heavier than their combustion-engined equivalents, a burden that’s mainly down to the batteries. It’s an issue manufacturers are working hard to eliminate through developments like solid state cells, new battery technologies and more efficient packaging.

What’s less well-known is that there’s an equally furious battle going on to reduce the weight of the electric motors that turn the batteries’ energy into motion. Every part of the motor is being slimmed down. Rotor and stator laminations made out of steel sheets can be replaced by lighter and cheaper soft magnetic compounds produced by injection moulding. Mild steel motor shafts can be switched to ones made from carbon-reinforced plastic and stainless steel. Motor windings can be lighter and more compact.