BorgWarner has secured its first business award for its aluminium-wire electric motor (eMotor) technology from a major Chinese original equipment manufacturer (OEM). The technology will be used in hybrid vehicles across multiple applications, including generator motors and traction motors for auxiliary drive systems, with production scheduled to begin in Q4 2026.
The motor uses aluminium-wire hairpin winding technology and marks the first commercial application of BorgWarner's aluminium-wire eMotor technology. The company has worked with the unnamed Chinese OEM across multiple product areas for more than 15 years.
The latest order expands the existing partnership into hybrid motor applications, with aluminium conductors and hairpin winding technology being integrated into BorgWarner's hybrid product portfolio.
According to BorgWarner, the aluminium-wire motor maintains peak torque and peak power levels comparable to a conventional copper-wire motor while reducing wire weight by more than 60% and costs by over 80% for equivalent specifications.
Aluminium-Wire eMotor Targets Hybrid Applications
The new technology is designed for generator motors in hybrid powertrains and traction motors used in auxiliary drive applications. This allows it to be incorporated across different hybrid vehicle architectures.
BorgWarner said the motor design, manufacturing processes and connection technologies have been optimised to meet the requirements of these applications. The programme is supported by the company's local product engineering and manufacturing capabilities in China.
Isabelle McKenzie, Vice President of BorgWarner and President and General Manager of PowerDrive Systems, said the programme combines aluminium conductors with the company's hairpin winding expertise to deliver weight and cost reductions while meeting the requirements of hybrid generator and auxiliary drive applications.