Ferrstron Powertrains Demonstrates 98% Efficient Rare-Earth-Free Heavy-Duty Motors

PUNE, MAHARASHTRA, INDIA, October 5, 2026 /CourierPR/ -- Ferrstron Powertrains, a Pune-based deep tech company, has achieved a significant milestone in the development of electric powertrains. The firm has demonstrated 98% efficient rare-earth-free heavy-duty motors, a breakthrough that could revolutionize the industry by eliminating the reliance on rare earth materials.

The company recently tested a physical prototype of its 150kW, 400Nm powertrain in a 2.3-ton Multi Utility Vehicle. This on-road testing validates the performance of the motor in full system integration in a real-world environment. The success of this prototype marks a pivotal step towards the commercialization of electric powertrains that can operate with ferrite magnets, which are significantly weaker than rare earth magnets in terms of magnetic strength and demagnetization resistance.

Ferrstron's technology compensates for the limitations of ferrite magnets through a series of innovations. These include the creation of high overall magnetic flux, higher armature reaction, and a multi-phase electromagnetic flux control algorithm that shifts the magnet's internal operating point away from the demagnetization limit. These advancements have been achieved through hundreds of simulations, followed by multiple physical prototypes and advanced tests over the past seven years.

The company's founder, Vishal Sharma, a veteran of advanced engineering simulation, leads the development of Ferrstron's core technology. Sharma, who previously worked at Dassault Systèmes and MSC Software, has been instrumental in creating a proprietary electromagnetic physics simulation technology that powers every aspect of the firm's innovation. This technology is crucial for the design of dual airgap motor architecture and the formulation of a multi-phase flux control algorithm.

Ferrstron's technology roadmap is based on stackable cartridge configurations, addressing a wide range of applications. The 400Nm Cartridge can be configured to powertrains of up to 800Nm, suitable for passenger vehicles and light commercial vehicles. The 1100Nm Cartridge can be stacked up to five cartridges, catering to powertrains from 1100Nm to 5500Nm, ideal for medium and heavy-duty trucks and buses, as well as distributed traction high-speed trains. The 8500Nm Cartridge, which can be stacked up to 10 cartridges, is designed for motors and generators from 1MW to 10MW, targeting electric and hybrid marine propulsion, high-speed onshore wind turbines, and data center gensets. The 1850kNm Cartridge, which can be stacked up to 11 cartridges, is aimed at 10MW to 21MW direct drive wind generators, specifically for offshore wind turbines.

Having achieved a Technology Readiness Level 6 after the latest on-road testing, Ferrstron is now embarking on the next phase of its development program. The company is in discussions with global Tier 1 and OEMs to eliminate the use of rare earth materials in their products. Ferrstron is also seeking investment to achieve Technology Readiness Level 8 and start production. The firm's next round of investment will be crucial in scaling up its technology and bringing it to market.

Ferrstron Powertrains is committed to developing high-efficiency, ultracompact, and rare-earth-free electric powertrains for heavy-duty electric propulsion and power generation. With its proprietary electromagnetic physics simulation technology and innovative solutions, the company is well-positioned to address the growing demand for sustainable and efficient electric powertrains in various sectors.