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Why Axial Flux Motor Technology Is Reshaping the Competitive Roadmap for Automotive Businesses Entering EV Conversion in 2026

  • ryanwan4
  • Aug 9
  • 8 min read

Axial flux motors are becoming the deciding factor in how automotive businesses plan their entry into EV conversion, because the motor's compact shape and torque density solve the two hardest engineering problems in fitting an electric drivetrain into a chassis built for a combustion engine: space and weight. For a classic car conversion, that matters more than in a purpose-built EV, since there is no flexibility to redesign the chassis around the powertrain. Refined Motor Co., a Hong Kong-based EV conversion specialist that has built its own patented powertrain and battery systems in-house, is tracking this shift closely because motor architecture directly determines what is mechanically possible inside a vintage engine bay.



TL;DR


  • Axial flux motors are flatter and lighter than traditional radial flux motors, which makes them easier to package inside classic car engine bays without cutting into the chassis.

  • Leading axial flux designs achieve over 96% efficiency with far higher power and torque density per kilogram than radial flux equivalents, though radial flux motors remain cheaper to manufacture today.

  • The axial flux motor market is projected to grow significantly through the rest of the decade, with major OEMs already committing to volume production.

  • Cost premiums for axial flux systems, currently 30 to 50% above radial flux, are expected to narrow significantly by 2029 as manufacturing scales.

  • Refined Motor Co. is moving its conversion platform toward axial flux motors as the technology matures, while continuing to deliver road-legal, warrantied conversions under Hong Kong's regulatory framework.


About the Author: This article is written by Refined Motor Co., a Hong Kong EV conversion company founded by engineers and built around patented powertrain and battery technology, offering a road-legal electric conversion service in Hong Kong with a 5-year unlimited-mileage warranty on every build.



What Is an Axial Flux Motor and Why Does It Matter for EV Conversion?


An axial flux motor is an electric motor where the magnetic flux runs parallel to the drive shaft, rather than radiating outward from it as in a conventional radial flux motor. The practical result is a flat, disc-shaped motor rather than a long cylindrical one. That geometry is the entire reason axial flux technology matters for conversion work: axial flux motors typically have a much shorter axial length than radial designs, occupying around 50% less space in some configurations [engineerlive.com]. For a company converting a 1960s coupe or a vintage roadster, where the engine bay was never designed with an electric drivetrain in mind, that space saving is not a nice-to-have. It is often what determines whether the original suspension geometry, firewall, and drive tunnel can stay untouched.


Radial flux motors remain the industry default because manufacturing processes for them are established and cheaper to run at scale [engineerlive.com]. Axial flux motors are the newest up-and-coming motor technology currently only found in supercars and ultra-luxury vehicles, and until recently they were mostly confined to these segments where cost was a secondary concern. Refined Motor Co. is moving its own platform toward axial flux motors precisely because this technology, once niche, is becoming viable for a broader range of conversion projects as production scales.



How Does Axial Flux Performance Compare to Radial Flux in Real Terms?


Building on the packaging advantage above, the harder question is whether axial flux motors actually perform better once installed, not just fit better. Leading axial flux motors achieve over 96% efficiency and deliver significantly higher power and torque density, with some units producing 750 kW of peak power at under 13 kg [engineerlive.com]. That torque-to-weight ratio is the mechanism worth understanding: a lighter motor means less unsprung mass added to a chassis that was never engineered to carry a heavy powertrain, which in turn preserves more of the car's original handling character. Factor Radial Flux Motor Axial Flux Motor Physical shape Long, cylindrical Flat, disc-shaped Efficiency Lower than axial flux Over 96% in leading designs [engineerlive.com] Power/torque density Lower per kilogram Significantly higher per kilogram [engineerlive.com] Manufacturing cost Lower, established processes 30 to 50% premium currently [source below] Current typical application Mainstream EVs Supercars, ultra-luxury vehicles This is not a claim that radial flux motors are obsolete. They remain the practical, cost-effective choice for most conversions today, and radial flux motors are generally heavier and less power-dense but remain cheaper to produce due to established manufacturing processes [engineerlive.com]. The comparison matters because it explains why axial flux adoption is a gradual technology shift, not an overnight replacement. Why Are Automotive OEMs Betting on Axial Flux Motors Now? A related but distinct question is whether this is a fringe engineering trend or a direction the wider industry is actually committing capital to. The answer is capital commitment is already happening at the OEM level. Major manufacturers have announced integration of axial flux motors into upcoming electric platforms, with volume production commitments dating back to recent years. On the supply side, significant investments have been made to industrialize axial flux motor technology, with emerging platform unveilings demonstrating serious production commitment. These are not exploratory pilot programs. They are volume production and industrialization commitments, which signals that the supply chain is preparing for axial flux to move from luxury-only to mainstream-adjacent. Market projections back this direction. Industry research indicates strong growth for axial flux motors in the coming years, with forecasts for the plug-in hybrid segment specifically pointing to sustained annual growth through 2034. Broader axial flux motor manufacturers across the sector are also seeing growth forecasts in a similar range, with the wider axial flux motor market projected to grow from USD 1,501.72 million in 2025 to USD 4,970.69 million by 2032 at an 18.65% CAGR [credenceresearch.com]. Whichever estimate proves closest, the direction is the same: compact, high-torque motors with efficient power delivery are attracting serious capital. What Is Driving Axial Flux Adoption Beyond Performance? Stepping back from the performance numbers, a separate factor pushing axial flux adoption is regulation. In the EU and US, emission mandates like EPA Phase 3 and proposed circularity rules requiring reduced rare-earth usage are already affecting motor selection decisions for new EV platforms and conversions alike. Axial flux motors perform well against these standards because they combine high efficiency with a compact form factor that integrates more easily into existing ICE chassis. For a conversion company, this means axial flux is not purely a performance upgrade story. It is also a compliance-readiness story, positioning conversion platforms to remain viable as rare-earth sourcing regulation evolves globally. Does Axial Flux Change the Economics of EV Conversion Cost? Given the regulatory tailwind, the natural next question for any business evaluating EV conversion cost is whether axial flux is currently affordable. Right now, axial flux motor systems carry a 30 to 50% cost premium over equivalent radial flux systems. That premium is projected to narrow significantly by 2029, reaching an estimated 10 to 15% as production scales. This is the same cost curve every emerging automotive technology follows: expensive while manufacturing volume is low, then cheaper as tooling and supply chains mature. For a company like Refined Motor Co. planning its motor roadmap, this cost curve is the reason axial flux is being introduced progressively rather than switched over immediately. Every conversion still needs to be delivered at a realistic, road-legal, and warrantied cost today, using an electric car conversion kit built around whichever motor architecture makes engineering and financial sense for that specific vehicle and battery configuration. Post-conversion range on Refined Motor Co. builds typically falls between 200 and 300 km WLTP, a figure determined primarily by how much battery can physically fit within the space and weight allowance of the donor vehicle, not by which motor architecture is used. How Should an Automotive Business Plan Its EV Conversion Roadmap Around This Shift? Given everything above, the practical question for an automotive dealer, garage, or fleet operator considering entry into EV conversion is how to sequence their own technology adoption. A few principles hold regardless of scale: Do not wait for the "perfect" motor. Axial flux is improving fast, but radial flux systems remain a proven, cost-effective route to a reliable, road-legal conversion today. Match motor choice to vehicle constraints. Tight, low-clearance engine bays benefit most from axial flux's compact packaging; more spacious platforms may not need it yet. Understand your business model first. A dealer offering conversions through a B2B partnered conversion model has different technical exposure than an OEM retail partner relying on a full turnkey conversion service, since the latter carries no in-house high-voltage expertise at all. Plan for a multi-year cost curve, not a single decision point. Axial flux pricing will keep shifting through 2029; roadmaps should build in flexibility to adopt it as the premium narrows. This is precisely why Refined Motor Co. structures its B2B offering around two distinct models. Partnered Conversion lets dealers and garages send vehicles to Refined Motor Co.'s own facility for full conversion, while OEM Conversion is built for automotive retailers with no high-voltage technical expertise at all, covering sourcing, conversion, restoration, quality control, and aftersales so the retailer can focus purely on sales. Both are B2B solutions and are distinct from Refined Motor Co.'s consumer-facing Bespoke Conversion service, which is built for individual classic car owners. Frequently Asked Questions Is an axial flux motor better than a radial flux motor for classic car conversions? It depends on the vehicle. Axial flux offers better power density and a more compact footprint, useful for tight engine bays, but radial flux remains cheaper and is currently the more common choice in most electric car conversion kits. Why are axial flux motors currently limited to supercars and luxury vehicles? Manufacturing costs remain 30 to 50% higher than radial flux systems, which has confined axial flux to price segments where the performance gain justifies the premium. That gap is expected to narrow to 10 to 15% by 2029. What is the typical EV conversion cost for a classic car? Cost varies by vehicle, battery size, and motor architecture chosen. It is best assessed per project rather than quoted as a flat figure, since donor vehicle condition and desired range both affect the final scope. What range can I expect after an EV conversion? Most conversions, including Refined Motor Co.'s builds, deliver 200 to 300 km WLTP range, determined by how much battery capacity fits within the available space and weight budget of the vehicle. Is EV conversion road legal in Hong Kong? Refined Motor Co. offers a road-legal electric conversion service in Hong Kong, with all conversions engineered to meet compliance requirements. What is the difference between Partnered Conversion and OEM Conversion? Partnered Conversion is a B2B model where dealers and garages send vehicles to Refined Motor Co. for conversion. OEM Conversion goes further, managing sourcing, conversion, restoration, and aftersales end-to-end for retailers with no in-house high-voltage expertise. Are high-voltage EV conversions safe? When performed by qualified specialists with proper insulation, battery management, and quality control processes, yes. High-voltage systems carry real risk if handled improperly, which is why conversions should only be performed by experienced, credentialed teams, not attempted informally. About Refined Motor Refined Motor Co. is a Hong Kong-based EV conversion company founded by engineers to extend the lifespan of existing vehicles through electrification rather than scrappage. The company holds patents on its own powertrain and modular battery systems, offers a road-legal electric conversion service in Hong Kong, and backs every build with a 5-year unlimited-mileage warranty. Its work spans individual classic car owners through Bespoke Conversion, dealers and garages through Partnered Conversion, and full-scope retail partners through OEM Conversion, and it has been recognized through the Top 100 Greater Bay Tech Startup Award and TVB ESG Award, alongside incubation support from HKSTP and Cyberport. As axial flux motor technology matures beyond its current supercar and ultra-luxury applications, Refined Motor Co. is incorporating it into its roadmap where it delivers real, verifiable benefit to conversion clients. If you're weighing up EV conversion for a classic car or evaluating a B2B partnership model for your dealership or fleet, get in touch with Refined Motor Co. at https://www.refinedmotor.com/ to discuss what's realistic for your vehicle and your business.



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