YASA opens UK-based axial flux motor facility with capacity to produce 25,000 motors annually
May 14, 2025
YASA Ltd, a wholly-owned subsidiary of Mercedes-Benz AG headquartered in Oxford, UK, has officially opened a newly upgraded manufacturing facility in Yarnton, near Oxford. Following a £12 million investment, the new factory will boost YASA’s axial-flux electric motor manufacturing capacity to over 25,000 units per year.
Reported to be the world’s most advanced axial-flux electric motor manufacturing facility, the Yarnton operation is also the UK’s first axial-flux electric motor super factory.
“With a multi-million-pound investment into our Yarnton facility, we have transformed our manufacturing capability and significantly accelerated our production capacity,” stated Tim Woolmer, YASA CTO and founder. “This latest initiative will enable us to apply our technology with even greater accuracy, pace and scale. Combined with YASA’s position as part of the Mercedes-Benz Group, the factory transformation consolidates YASA’s role as a global leader in developing high-performance, high-efficiency axial-flux e-motors.“
Developed for electric and hybrid vehicles, YASA’s axial flux motors deliver up to four times greater performance than other electric motors on the road today. The design contains stators made from soft magnetic composite (SMC) powders.
“As a company, we have come a long way since our humble origin as an Oxford University start-up. However, we are still driven by the same passion, spirit and determination to create the world’s most advanced electric mobility technology solutions,” continued Woolmer.
The new 5,600 m2 facility incorporates cutting-edge manufacturing technologies designed specifically to meet YASA’s requirements. These include the addition of four new, uniquely constructed coil and bar manufacturing cells with state-of-the-art CNC coil winding, assembly and impregnation processes. New laser stripping and brazing, increased rotor balancing accuracy, new high-capacity ovens, stator laser welding and complete stator quality control, covering dimensional, electrical and leak testing.
The facility brings all production processes under one roof, with significantly enhanced automation and highly efficient production lines. The company stated that these advances will enhance YASA’s capability to create complete motor sets while improving repeatability and reliability and introducing even greater flexibility levels by overcoming bottlenecks in the component supply chain.
Richard Firmstone, YASA’s Operations Director, explained, “We have transformed the manufacturing processes to enable an enhanced operating philosophy. Manufacturing in motor sets to optimise flow, improving safety, quality, and efficiency. Enabling full process and material traceability, creating full flexibility to mitigate risk and deal with fluctuations in customer demand effectively.”
YASA’s longstanding relationship with the Advanced Propulsion Centre UK (APC) is reported to have helped enable the original development of its Yarnton facility. While this latest expansion has been privately funded, YASA continues to work closely with the APC on future generations of axial flux technology.
“Each of the numerous technical manufacturing advances we have implemented during the factory transformation consolidates YASA’s ability to outpace and outperform all existing radial flux technology by delivering more compact, lightweight electric propulsion systems,” added Andy North, YASA Commercial Director. “YASA is now better placed to meet the needs of our OEM customers, such as Ferrari and Lamborghini, and new customers on a global scale than ever before.”
High-profile users of YASA’s axial flux technology include both Ferrari and Lamborghini, as well as Mercedes Benz.
Joerg Miska, YASA’s CEO, concluded, “This vastly improved facility is another important step in YASA’s ongoing strategy to further expand its product and customer portfolio. The new super factory delivers increased flexibility, efficiency, and quality, positioning the company for diverse business opportunities. Thanks to their ultra-compact design and exceptional torque and power, YASA motors are perfectly suited for high-performance hybrid vehicles and other fully electric applications across complementary sectors.”
Discover more about SMC’s for electric motors in the current issue of Metal Powder Technology magazine:
