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Other automakers follow Tesla into rare earth metal-free powertrains

Credit: Tesla Manufacturing/X

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Tesla and others are looking to end the use of rare earth metals in future electric vehicle (EV) motors, with U.S., European and Japanese automakers all considering the move to help reduce reliance on China.

During the company’s Investor Day event earlier this year, Tesla’s Vice President of Powertrain Engineering Colin Campbell announced that the company’s next-generation powertrain would include a permanent magnet motor with zero rare earth metals. Automakers including General Motors (GM), Jaguar Land Rover (JLR), Nissan and more, along with the supplier BorgWarner, are all developing, researching or have already created motors with low- or zero-rare earth materials, according to a recent report from Reuters.

Nissan has taken its attempts further than previously reported in the development of new magnet-free externally excited synchronous machine (EESM) motors, which utilize an electrical current to create a magnetic field. Eventually, the Japanese automaker plans to phase out the use of rare earth metals entirely through EESM development and the use of permanent magnet motors. Nissan also currently utilizes an EESM motor in the Ariya crossover.

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“This is an important contribution to making us a little more independent of China,” said Otmar Scharrer, CTO of German supplier ZF.

ZF has created an EESM motor that Scharrer said offers similar performance and overall size to those in permanent magnet motors.

Currently, the processing and mining of the 17 minerals known as rare earth metals are dominated by China, and many have sounded the alarm on relying too heavily on the country — especially after the government announced a recent export ban of gallium and graphite, both of which are crucial for EV production.

There are also sustainability reasons to move away from the use of these minerals, along with those related to bolstering the home supply chains of individual markets. Other rare earth materials like neodymium and dysprosium require the use of solvents and generate toxic waste, opposing current environmental standards and goals.

Detroit-based company Drive System Design is working on motors free of rare earth metals with three different automakers, and the firm’s Director of Engineering Business Development, Ben Chiswick, also highlights the environmental benefits of the shift.

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“If you get it right, you’ve got a much more sustainable product,” Chaswick said.

BMW has reportedly conducted several years of research into motors without rare earth materials.

“It was not a home run… but it works very well without rare earths,” said Uwe Deuke, BMW’s lead engineer for the EESM motor being developed for its next-generation vehicle.

Even automakers that aren’t phasing out rare earths entirely are reducing their content dramatically in upcoming EV designs. Mercedes-Benz, for example, will use almost no heavy rare earth materials in its next-generation EV, although it will still be a permanent magnet motor using a small amount of the minerals.

Tesla lithium refinery to start production in Q1 2024

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What are your thoughts? Let me know at zach@teslarati.com, find me on X at @zacharyvisconti, or send your tips to us at tips@teslarati.com.

Zach is a renewable energy reporter who has been covering electric vehicles since 2020. He grew up in Fremont, California, and he currently lives in Colorado. His work has appeared in the Chicago Tribune, KRON4 San Francisco, FOX31 Denver, InsideEVs, CleanTechnica, and many other publications. When he isn't covering Tesla or other EV companies, you can find him writing and performing music, drinking a good cup of coffee, or hanging out with his cats, Banks and Freddie. Reach out at zach@teslarati.com, find him on X at @zacharyvisconti, or send us tips at tips@teslarati.com.

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Tesla Semi futuristic sci-fi acceleration sound will never get old

Videos that capture the Semi moving at speed are most notable due to their sheer cool factor.

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Credit: Tesla Owners Silicon Valley/X

The Tesla Semi is not yet in mass production, but the company has accumulated over 7.9 million miles across its test fleet. With Tesla using the Semi for its operations, it is no surprise that sightings of the Class 8 all-electric truck have been abounding. 

These sightings from Tesla enthusiasts vary, but those that capture the the Class 8 all-electric truck moving at speed are most notable, possibly due to their sheer cool factor.

Tesla Semi’s Roar

There is something that just stands out with the Semi, particularly on the road. While the Semi does not have the Cybertruck’s brutalist, angular design, it is still very striking because it’s such a massive machine that moves far too quietly for its size. This is, of course, one of the reasons why the vehicle also becomes extra noteworthy when it fires up its electric motors and accelerates.

Take this video from Tesla Owners Silicon Valley, for example, which shows the all-electric hauler accelerating while pulling what appears to be a full load. In these situations, the Tesla Semi actually becomes audible, but unlike traditional diesel-powered truck, the Class 8 all-electric truck “roars” with its own, unique futuristic, sci-fi sound. In such situations, one could feel the Semi’s raw power, which comes from its three independent motors on its rear axles.

Tesla Semi Ramp

Tesla has been promoting the Semi quite a bit as of late, and recent reports have suggested that the company is putting in a lot of effort to prepare the vehicle for its production in Nevada. Tesla’s Careers website has gone live with over 80 Semi-related job openings recently as well, and a recent report has suggested that Tesla has ramped the Semi’s factory workers in Nevada to over 1,000 employees.

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The company has even shared an update video of the Semi factory’s progress near Giga Nevada, as well as the design of the vehicle’s new logo. The Semi’s updated logo is quite interesting as it features elements from the Tesla Model 3’s first logo, which was unveiled way back in 2016.

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Robots like Tesla Optimus are a $5 trillion opportunity: analyst

This massive opportunity could be tapped by Tesla, thanks to its Optimus humanoid robot.

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Credit: Tesla

Morgan Stanley analysts have estimated that the humanoid robot market could offer a $5 trillion opportunity by the middle of the century. This massive opportunity could be tapped by Tesla, thanks to its Optimus humanoid robot.

The analysts, however, noted that the humanoid robots will likely be mostly used in industrial and commercial deployments.

The Estimates

Estimates from Morgan Stanley analysts point to humanoid robots hitting $5 trillion in global revenue by 2050. This, the analysts noted, would be about double the total revenue of the 20 largest automakers in 2024. In 2050, Morgan Stanley analysts estimated that there might be about 1 billion humanoid robots deployed.

As noted in a report from Investing.com, the shift to humanoid robots would be gradual. By 2035, the analysts estimated that just about 13 million humanoid robots will be in use, most of which will be used in industrial and commercial settings. Even in 2050, when the analysts estimated that 1 billion humanoid robots will be in use, an estimated 90% might still be used in industrial and commercial settings.

The advent of humanoid robots will likely be felt in the labor sector, Morgan Stanley analysts noted. By 2030, the analysts noted that humanoid robots could replace about 40,000 jobs. Just ten years later, in 2040, the number of jobs that robots could take over could balloon to 8.4 million. By 2050, the analysts noted that 62.7 million humans may end up watching humanoid robots do their jobs.

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Tesla Potential

Morgan Stanley noted that companies like Tesla, which control the “brains, bodies, branding and ecosystems” of the humanoid robots, would be able to offer the highest value. This is good news for Tesla’s Optimus program, as it is a product that is designed to be produced at an extreme scale. During the Q1 2025 All Hands meeting, Elon Musk reiterated the idea that Optimus could very well become the biggest product of all time.

Most importantly, Musk also stated that Tesla is internally aiming to acquire enough resources to produce 10,000 to 12,000 Optimus robots this year. But even if Tesla just manages half of this number, or about 5,000 Optimus robots this year, it would already be impressive.

“Even 5,000 robots, that’s the size of a Roman legion, FYI, which is like a little scary thought. Like a whole legion of robots, I’ll be like ‘whoa.’ But I think we will literally build a legion, at least one legion of robots this year, and then probably 10 legions next year. I think it’s kind of a cool unit, you know? Units of legion. So probably 50,000-ish next year,” Musk stated.

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SpaceX set to launch Axiom’s mission for diabetes research on the ISS

Axiom’s Ax-4 will test CGMs & insulin stability in microgravity—potentially reshaping diabetes care for Earth & future astronauts.

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(Credit: SpaceX)

Axiom Space’s Ax-4 mission is set to launch on a SpaceX Falcon 9 rocket. Ax-4 will advance diabetes research in microgravity, marking a milestone for astronaut health.

Axiom Space’s fourth crewed mission is scheduled to launch with SpaceX on May 29 from NASA’s Kennedy Space Center in Florida. The Ax-4 mission will carry a diverse crew and a record-breaking scientific payload to the International Space Station (ISS).

The Ax-4 crew is led by Axiom’s Peggy Whitson and includes Shubhanshu Shukla from India, Sławosz Uznański from the European Space Agency, and Tibor Kapu from Hungary. The mission represents firsts for India, Hungary, and Poland, with Uznański being Poland’s first astronaut in over 40 years.

Ax-4 will conduct nearly 60 science investigations from 31 countries during its two-week ISS stay. A key focus is the “Suite Ride” initiative, a collaboration with Burjeel Holdings to study diabetes management in microgravity.

“The effort marks a significant milestone in the long-term goal of supporting future astronauts with insulin-dependent diabetes (IDDM), a condition historically deemed disqualifying for spaceflight,” Axiom noted. The mission will test Continuous Glucose Monitors (CGMs) and insulin stability to assess their performance in space.

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Axiom explained that testing the behavior of CGMs and insulin delivery technologies in microgravity and observing circadian rhythm disruption could help diabetes experts understand how CGMs and insulin pens can improve diabetes monitoring and care in remote or underserved areas on Earth. The research could benefit diabetes management in isolated regions like oil rigs or rural areas.

The mission’s findings on insulin exposure and CGM performance could pave the way for astronauts with diabetes to safely participate in spaceflight. As Axiom and SpaceX push boundaries, Ax-4’s diabetes research underscores the potential for space-based innovations to transform healthcare on Earth and beyond.

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