BorgWarner secures first order for aluminium-wire electric motor technology

BorgWarner has won its first commercial order for an electric motor developed with aluminium-wire hairpin winding technology. The US automotive supplier will provide the new eMotor to a major Chinese automaker for use in hybrid vehicles, bringing the technology into its first production application.

The motor uses aluminium-wire hairpin winding technology and is designed for hybrid vehicles. Its applications include generator motors and traction motors for auxiliary drive systems, with production scheduled to begin in the fourth quarter of 2026.

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Compared with conventional copper-wire motors with similar specifications, BorgWarner's aluminium-wire solution reduces weight by more than 60 per cent and cost by over 80 per cent, while maintaining peak torque and power.

The order extends BorgWarner's relationship with the Chinese automaker, with the two companies having worked together across several product areas for more than 15 years.

Isabelle McKenzie, Vice President of BorgWarner and President and General Manager of PowerDrive Systems, said the technology combines aluminium conductors with the company's experience in hairpin winding to achieve lower weight and cost. 

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She added that BorgWarner had optimised the motor design, manufacturing processes and connection technologies for hybrid generator and auxiliary drive applications, drawing on its local engineering and manufacturing capabilities.

The aluminium-wire technology can be used across different hybrid vehicle architectures, giving automakers greater flexibility in designing generator motors and traction motors for auxiliary drive applications.