Mercedes-Benz has commenced large-scale production of its new electric axial flux motor at its Berlin-Marienfelde plant.
With the launch of large-scale production of this revolutionary drive system, the company’s oldest manufacturing site is opening a new chapter in its history spanning more than 120 years. The compact high-performance motor is celebrating its world debut in a production vehicle in the new Mercedes-AMG GT 4-Door Coupé.
Founded in 1902, the Berlin-Marienfelde plant has been part of the global powertrain production network for decades. Since 2022, it has also been home to the Mercedes-Benz Digital Factory Campus. Mercedes-Benz is now establishing the site as a centre of excellence for the manufacture of high-performance electric motors.
Leadership Statements on Technological Significance
Michael Schiebe, Member of the Board of Management of Mercedes-Benz Group AG responsible for Production, Quality & Supply Chain Management, stated that with the start of large-scale series production of the axial flux motor in Berlin-Marienfelde, they are bringing a pioneering innovation for electromobility into industrial reality.
In doing so, they are sending a strong signal of technological leadership, operational excellence, and transformation of the automotive industry in Germany.
Patrick Schnieder, German Federal Minister of Transport, stated mastering the demanding axial flux technology is a major opportunity for the German and European automotive industry. This innovative electric motor helps establish a strong foothold in the premium segment, sending a powerful signal about Germany’s strength as an industrial location.
Ute Bonde, Senator for Urban Mobility, Transport, Climate Action and the Environment for the state of Berlin, stated the production launch marks the beginning of a new chapter for innovative vehicle technology, industrial value creation, and transformation of mobility. Berlin needs success stories like this, which inspire confidence in change, secure jobs, and strengthen its position in international competition.
Manufacturing Complexity and Process Innovation
By starting large-scale series production of the axial flux motor, a technological vision is becoming industrial reality. What was long considered barely feasible due to its complexity is now being manufactured in large series in Berlin-Marienfelde.
In total, production comprises 98 process steps. Sixty-five of these are being used for the first time at Mercedes-Benz, while 35 processes are new worldwide. The technologies developed for this purpose have resulted in more than 30 patent applications.
Across around 30,000 square metres of production space, in three halls and on seven production lines, Mercedes-Benz combines highly automated manufacturing processes, laser technology, intelligent control systems, AI-based quality control, and the expertise of highly skilled employees.
Copper Coil Manufacturing Precision
The start of large-scale series production places exceptional demands on precision, process reliability, and automation. The motor’s compact design and high-power density require manufacturing methods newly developed specifically for this application and industrialized for large-scale production.
One example is manufacture of copper coils. To achieve the high-power density of the axial flux motor, rectangular copper wire is used in the stator, allowing more copper to be installed in the same installation space than with round wire.
However, the wire must be bent at high speed into tight radii without forming creases, damaging insulation, or reducing cross-section. Mercedes-Benz has developed a special process combining maximum precision with industrial cycle capability.
The interconnection of coil packages in the stator is also technologically demanding. Each coil end must be connected to the corresponding interconnection wire within a very confined installation space without causing thermal damage to adjacent plastic structures.
The solution is highly precise laser connection of copper wires, enabling minimal energy input at the welding point while maintaining very short process time.
Laser Polymer Welding and AI Quality Control
Another example of precision-critical manufacturing processes is polymer welding. Simultaneous laser transmission welding of plastic components in the drivetrain requires highest geometric accuracy and minimally invasive energy input to avoid damage to surrounding areas.
AI-supported optical real-time quality control documents the joint immediately and supports process reliability. During conditioning of joining partners, AI-based image processing detects exact position of a component, places virtual protection zones over sensitive areas, and ensures the laser precisely processes only intended surfaces.
The components joined in this way are both oil-pressure-tight and capable of withstanding high mechanical loads.
Final Assembly Manages Extreme Magnetic Forces
The final assembly, known internally as the “wedding,” is particularly impressive. During this process, the stator is positioned between two rotor discs fitted with magnets and permanently joined. Magnetic forces of up to 9 kN—equivalent to around 900 kilograms—act on the components. At the same time, the stator must remain within the magnetic centre plane with tolerance of less than 0.1 millimetres.
An innovative control algorithm corrects position in the final 0.5 seconds of the process using high-frequency control impulses. What matters here is not force alone, but intelligent control, sensitive sensor technology, and precise process management.
Axial Flux Technology Design Principles
The British electric motor specialist YASA built upon the fundamental principle of the axial flux motor and developed an innovative prototype on which the current motor is based.
Since YASA became a wholly owned subsidiary of Mercedes-Benz AG in 2021, Mercedes-Benz has consistently further developed the technology for both the product and production process to meet requirements of automotive mass production, high performance, and continuous load capability. The axial flux motor on the front axle reaches speeds of more than 15,000 revolutions per minute.
In contrast to conventional radial flux motors, the electromagnetic flux in an axial flux motor runs parallel to the axis of rotation. The key components are arranged in disc-shaped layout: two rotors sandwich the stator from left and right.
This design enables especially compact motor architecture, high power and torque density, and new freedoms in drivetrain packaging. In the new Mercedes-AMG GT 4-Door Coupé, the motor at the front axle is just under nine centimetres wide; the two motors at the rear axle each measure around eight centimetres in width.
The three axial flux motors are integrated per axle into High Performance Electric Drive Units (HP.EDU), combined with compact input planetary gearbox in a single housing.
Performance Demonstration and Record Achievement
The new Mercedes-AMG GT 4-Door Coupé clearly demonstrates the performance potential of this technology. The all-electric performance model accelerates from 0 to 100 km/h in as little as 2.1 seconds and reaches top speed of 300 km/h with the Driver’s Package.
Its capabilities were also demonstrated the previous year by a spectacular record run in Nardò with the technology demonstrator CONCEPT AMG GT XX: over seven days and 13 hours, it covered more than 40,000 kilometres and set 25 long-distance records.
Digital Factory Campus Integration
The start of large-scale series production is closely linked to strategic further development of the Berlin-Marienfelde site. With the Mercedes-Benz Digital Factory Campus, the plant has assumed a central role in digitalisation of production within the global Mercedes-Benz production network since 2022.
The campus serves as a real production environment for development and testing of digital applications based on the MO360 production ecosystem.
With industrialisation of the axial flux motor, Berlin-Marienfelde brings together key future fields: high-performance electric drive systems, digital production, and intelligent automation. As the oldest producing Mercedes-Benz site, it is taking on a central role in transferring new technologies into scalable, quality-assured large-scale production processes.