Sona Comstar Develops Rare Earth-Free Ferrite Motor for EVs

Sona Comstar has successfully developed and validated a rare earth-free, ferrite-assisted synchronous reluctance motor for electric two-wheelers, three-wheelers, and light commercial vehicles. 

This breakthrough comes as a direct response to China’s April 2025 export curbs on heavy rare-earth magnets, which disrupted global EV supply chains and impacted Sona’s Q1 production.

The new motor eliminates reliance on costly and geopolitically sensitive rare-earth elements like neodymium and dysprosium, replacing them with widely available ferrite magnets. While traditional permanent magnet synchronous motors (PMSMs) (used in 70-80% of EVs) offer high torque density, they suffer from performance degradation at high temperatures. 

Sona Comstar has optimised the ferrite motor’s design to offset lower magnetic strength through enhanced thermal stability and structural efficiency, making it a viable, cost-effective alternative.

The move aligns with India’s push for self-reliance in EV components. Ola Electric recently secured GARC certification for its ferrite motor, while Simple Energy began commercial production of heavy rare-earth-free units. TVS Motor and startups like Chara Technologies are also advancing similar solutions.

Sona Comstar’s new launch ensures production continuity, could reduce import dependency, and supports lower-cost EV platforms, critical for mass adoption in price-sensitive segments.

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