Can electric mobility scale without depending on rare earth materials? As global EV growth becomes increasingly tied to supply-chain dependencies, Chara Technologies is rethinking the foundation of electric mobility with rare earth-free motor technology designed and built in India. In a conversation with EFY’s Nitisha Dubey, Bhaktha Keshavachar discusses the company’s motor innovation and its implications for the future of electric mobility.
Q. What does Chara Technologies do, and what kind of products is the company developing?
A. We focus on designing and manufacturing rare earth-free electric motors and integrated controllers for mobility and industrial applications. After years of dedicated research and development, we have introduced products ranging from 8kW to 35kW for applications including two-wheelers, three-wheelers, compact four-wheelers, and industrial machinery.
Q. What core innovations enable your motors to compete with conventional ones?
A. Our innovation lies in three areas. First is motor design, where we use the principle of reluctance to generate torque. Second is software, which plays a critical role in controlling the motor’s behaviour. Reluctance motors are inherently non-linear and difficult to control, so advanced algorithms are essential. Third is integration. We design the motor and controller together, unlike the traditional approach, where they are sourced separately. This integrated approach improves both efficiency and overall performance.
Q. How do your motors compare in terms of performance?
A. We match conventional motors in peak efficiency, torque, and power. Where we outperform them is duty-cycle efficiency. Our motors maintain more consistent efficiency across different speeds and operating conditions, enabling better real-world performance. For EVs, this results in improved range and more efficient energy use across the entire drive cycle.
Q. How do you optimise efficiency in real-world conditions?
A. Our motors maintain a flatter efficiency curve across different operating conditions. This means they perform better in stop-and-go traffic, which is common in urban environments. As a result, vehicles using our motors can achieve better range without increasing battery size, reducing both cost and weight.
Q. What about thermal performance and cooling?
A. Our motors benefit from better thermal characteristics due to their larger size. Unlike permanent-magnet motors, they do not face risks of demagnetisation at high temperatures. Cooling mechanisms are similar to conventional systems, using air cooling for lower-power applications and liquid cooling for higher-power ones.
Q. How does the cost of your motors compare to traditional solutions?
A. Currently, we match the pricing of conventional motors. As production scales, our motors are expected to become 15 to 20 per cent more affordable by eliminating the need for expensive rare earth magnets. Additionally, improved efficiency reduces operational costs for users.
Q. Which segments are most ready to adopt your technology?
A. The strongest product-market fit is in two-wheelers, three-wheelers, small four-wheelers, and off-highway applications such as tractors and forklifts. High-speed passenger cars remain a work in progress, and we are actively developing solutions for this segment.
Q. What were the biggest engineering challenges you faced?
A. The two main challenges were controlling the non-linear behaviour of reluctance motors and achieving high-speed performance. We addressed control issues through advanced software algorithms and detailed motor characterisation. For high-speed operation, we had to solve mechanical challenges related to rotor design and structural integrity. These improvements have enabled our motors to operate at competitive speeds, with plans to push performance even further.
Q. How do you manage manufacturing in India despite supply chain limitations?
A. For the motor itself, all materials, including steel, aluminium, copper, and ferrite magnets, are sourced domestically. The challenge lies in the semiconductors used in controllers, which still need to be imported. However, these components can be sourced from multiple countries, reducing dependency on a single supplier. With developments such as Tata Electronics and the emergence of semiconductor players in India, we expect this gap to narrow over time.
Q. How does your technology reduce global supply-chain risks?
A. Traditional motors rely on rare earth materials, most of which are controlled by China. This creates geopolitical and supply-related risks. By eliminating rare earth materials entirely, our motors provide a more stable and independent supply chain, which is especially important for global manufacturers.
Q. Are you working with any partners or customers?
A. Yes, we are working with a range of start-ups, mid-sized companies, and established OEMs across different segments. We are also in discussions with larger players and expect broader adoption in the coming years.
Q. How future-proof is your technology?
A. Our approach is highly adaptable because software plays a central role. We can continuously improve performance through updates. While new technologies, such as rare earth-free magnets, may emerge in the future, they are likely still years away. In the meantime, we are also exploring improvements in materials such as advanced electrical steel to further enhance performance.
Q. What is your approach to sustainability and waste management?
A. We use materials such as steel, aluminium, and copper, all of which are highly recyclable. Manufacturing waste is minimal and is handled through standard recycling processes. For electronics, we are exploring ways to introduce take-back and recycling programmes.
Q. What are your future plans?
A. We plan to expand internationally and significantly scale up manufacturing capacity. Currently, we can produce around 25,000 motors annually, and we aim to increase this to 100,000 in the near future. Alongside scaling production, we will continue investing in research and development to enhance performance and enter new application areas.
