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BEST ELECTRIC MACHINE → THE BOTTOM LINE
Best Electric Machine (BEM) is a U.S.-based electric motor-generator system or electric machine system (EMS) manufacturer commercializing SYNCHRO-SYM™, the only practical electromagnetically symmetric, active-rotor EMS architecture that eliminates reliance on rare-earth permanent magnets (RE-PM) and their associated geopolitical and supply-chain risks. But unlike other rare-earth-free passive-rotor alternatives—such as induction, reluctance, or DC field-wound machine systems—the active-rotor SYNCHRO-SYM™ significantly improves power density, efficiency, or system cost.
BEM supports any production volume or custom design requirement through MOTORPRINTER™–a programmable, additive-manufacturing platform capable of securely fabricating high-performance axial-flux electric machines using advanced core materials, without conventional retooling overhead or material waste–and BEM-CAD™–a computer-aided design tool for the classic symmetric, active-rotor (and active stator) electric motor-generator system architecture. Production scales modularly through replication of the compact, portable, low waste MOTORPRINTER™ additive-manufacturing platform.
Together, SYNCHRO-SYM™, BEM-CAD™, and MOTORPRINTER™ establish a sovereign U.S. electric machine platform that combines the unmatched price-performance of its rare-earth-free symmetric EMS with its rapid, just-in-time, reprogrammable domestic manufacturing, thereby strengthening national infrastructure, energy security, and supply chain resilience.
SYNCHRO-SYM™ is not a new theoretical construct, but the practical realization of the classic symmetric, active-rotor (and active stator) electric motor-generator system circuit and control architecture made possible by modern advances in commercially practical power electronics, digital control bandwidth, integrated system design, enabling brushless and sensorless real-time emulation control invention, and advanced axial-flux manufacturing capabilities. It provides a truly digitized, magnet-free, drop-in replacement for today’s variable-speed, asymmetric, passive-rotor electric motor-generator systems, including induction, reluctance, field-wound, and permanent-magnet architectures—delivering:
2× to 8× improvement in nominal performance per dollar
Greater than 8× peak torque capability, enabling practical next-generation gearless electric vehicles (EV) with high-capacity, regenerative brake-by-wire.
Axial-Flux FormFactor employing the same rotor and stator disks, reconfigured by software.
SYNCHRO-SYMTM is technically proven and ready for immediate commercialization with rapid design and reprogrammable, stateside additive manufacturing, a truly software-defined EMS targeted for 2026-2027.
Even today’s most advanced EV motors—including high-performance axial-flux designs such as those developed by YASA Limited and adopted by Mercedes-Benz—remain optimized passive-rotor machines operating near the classical limits of that architecture and packaging. SYNCHRO-SYM upgrades these machines to an active-rotor architecture that delivers additional power within the same package.
SYNCHRO-SYM™ uses a truly unique active-rotor electric-machine architecture that adds working power within the same design specification and package footprint—effectively doubling whatever performance competing motor systems may claim under the same constraints, placing SYNCHRO-SYM in a class of its own—by physics, not hype.
BEM also provides a uniquely superior low overhead, low waste, portable, secure, reprogrammable, additive manufacturing method that enables axial-flux electric machines—including SYNCHRO-SYM—employing high-performance amorphous layered magnetic materials and enhanced thermal-management capability.
Rare-earth permanent-magnet (RE-PM) electric-machine systems represent today’s highest-performing conventional technology, achieving widespread market adoption. However, their dependence on highly concentrated rare-earth supply chains introduces significant material-resilience and geopolitical risks. As supply-chain security remains uncertain, some manufacturers are pursuing rare-earth-free electric-machine systems that reduce these risks, typically accepting lower performance as the tradeoff.
SYNCHRO-SYM™ uniquely provides a permanent-magnet-free alternative that improves performance, enabling supply-chain resilience without sacrificing system capability and thereby strengthening national security.
BEST ELECTRIC MACHINE → WHY SYNCHRO-SYM™ CHANGES EVERYTHING
Fundamentally arising from the electromagnetically asymmetric circuit and control architecture of an active stator assembly with an independently excited multiphase winding set (active winding set) paired with a passive rotor assembly using permanent magnets (PM), reluctance saliencies, DC field windings, or slip-induction windings, and governed by offline compensatory derivatives of field-oriented control (FOC) or direct-torque control (DTC), the asymmetric electric-machine system (A-EMS) architecture in use today is intrinsically constrained in scalability, power density, and core utilization, and remains dependent on fixed-tooling manufacturing that requires die retooling and lamination re-inventory for changes in power rating or production volume.
Note: Permanent magnets, reluctance saliencies, field windings, and induction windings do not independently provide controllable bidirectional electrical working power. Their electromagnetic contribution depends upon excitation supplied elsewhere within the machine system and are therefore classified as passive rotor elements. An active assembly independently provides bidirectional working electromagnetic power to the electromechanical energy-conversion process through its own electrical power port while occupying approximately half of the electric-machine package, associated loss, and manufacturing cost. In contrast, a passive assembly does not independently provide bidirectional working electromagnetic power through its own electrical power port but occupies approximately half of the electric-machine package, associated loss, and manufacturing cost.
Free from the constraints of today’s asymmetric electric-machine system (A-EMS) architecture, SYNCHRO-SYM™ has the classic electromagnetically symmetric circuit and control architecture comprising an active-stator assembly paired with an active-rotor assembly, which scales across EV, wind, aerospace, and commercial applications. As the only practical “symmetric” electric motor-generator system (S-EMS), SYNCHRO-SYM™ provides:
Active Stator + Active Rotor Symmetry — both halves independently provide bidirectional working electromagnetic power to the electromechanical conversion through their own electrical power ports, performance-to-price grounded in physics—not marketing spin.
Maintenance-free, Brushless & Sensorless Real Time Emulation Control (BRTEC™) — compact solid-state, quantum level stabilization with a maintenance-free, brushless, symmetrically bidirectional, inherent soft switching, pure sinusoidal, magnetic-sharing™, direct AC-to-AC power conversion method at half the current rating; no bulky, costly DC link stage — inherently providing full rotor and stator metrics for superior reliance and automatic sensor-less optimization. Highly adaptable, BRTEC conveniently enables an ultra-high-performance, symmetrically bi-directional, multiphase, isolated EV micro-distribution bus and battery recharger.
Twice the constant torque speed range (CTSR) for a given torque, voltage, excitation frequency, and airgap flux density design—tantamount to twice the rated power, half the system loss, and lower cost within packaging similar to today’s asymmetric electric-machine systems.
Integrally unified electric motor-generator and control technology — not the mated, disparate circuit and control technologies of today’s A-EMS, evolving from different disciplines — compact solid-state BRTEC fits within the axial-flux annulus for another level of integration and power density.
Just-In-Time Additive Manufacturing — enables rapid, low waste, scalable, secure, and reprogrammable production with MOTORPRINTER™, an axial-flux electric motor 3D Printer Method, and BEM-CAD™, the only EMS CAD with SYNCHRO-SYM extension and cross-analysis.
Future-Ready Architecture — most compatible symmetric circuit and control technology for retrofitting the next-generation EMS, including the superconductor EMS.
Expert-Driven Culture — engineering excellence, customer focus, and principled innovation.
Most manufacturers classify electric motor-generator systems (EMS) according to passive-rotor technologies—including permanent magnets, induction windings, reluctance saliencies, and field-excited windings—employing an active stator with a directly excited multiphase winding set for the independent production of working electromagnetic power and controlled by some derivative of field-oriented control (FOC).
BEM classifies electric motor-generator systems into two fundamental electromagnetic architectures: the Asymmetric EMS (A-EMS), comprising an active stator with any passive-rotor technology, and the Symmetric EMS (S-EMS), comprising both an active stator and an active rotor operating under Maintenance-free, Brushless and Sensorless Real-Time Emulation Control (BRTEC).
In BEM terminology, the S-EMS represents the more fundamental electromagnetic architecture underlying classic electric machine theory, while the A-EMS represents the practical specialization that has historically dominated electric machine design because the real-time coordinated control of an active rotor was not practical until recent advances in power electronics, high-frequency magnetics, digital control, advanced materials, and additive manufacturing, enabling invention.
“Rare Earths in Electric Vehicle Motors: What You Need to Know” provides a comprehensive overview of today’s electric motor-generator systems (EMS) and the geopolitical implications of their reliance on rare-earth materials in electric vehicles (EVs). The article categorizes EV motor technologies as induction, reluctance, DC field-wound, or permanent-magnet machines. However, this classification focuses on differences in passive rotor technology while overlooking the more fundamental electromagnetic distinction between asymmetric passive rotor and symmetric active rotor EMS architectures.
All of the motor categories discussed in the article share a common, non-optimal asymmetric electromagnetic structure: an active-stator that supplies essentially all of the working electrical power and a passive-rotor that does not independently contribute additional working power to the electromechanical energy conversion process. While rotor technologies differ—whether induction windings, reluctance saliencies, field windings, or permanent magnets—the passive-rotor still contributes significantly to system loss, cost, complexity, and size through its electromagnetic interaction with the active-stator and controller derivatives with destabilizing offline processing delays.
Notably absent from the discussion is the classical electromagnetic principle that the optimal electric machine fundamentally begins with electromagnetic symmetry in which both the stator and rotor are independently active participants in the energy conversion process. Already, over a half-century of classical laboratory research validated that in such a symmetric architecture, the rotor contributes an additional increment of working power alongside the stator, increasing electromagnetic utilization and potentially improving power density, efficiency, and cost effectiveness in the same package footprint as the asymmetric EMS.
The article unintentionally highlights an important historical reality: although the concept of a symmetric electric machine has long been understood in electromagnetic theory, practical implementation was largely abandoned due to the stability limitations of available control technology. Modern advances in power electronics, computational capability, magnetic materials, and manufacturing technologies enabled the essential invention of Brushless & Sensorless Real-Time Emulation Control (BRTEC™), which in turn enables the commercialization of a maintenance-free, symmetric EMS in which both the stator and rotor combine their working power to the electromechanical energy conversion process. Called SYNCHRO-SYM, this breakthrough opens a pathway toward symmetric electric propulsion systems with substantially higher electromagnetic utilization, greater power density, and reduced dependence on rare-earth permanent magnets, thereby expanding the article’s design space beyond the passive-rotor electric machine architectures that currently dominate contemporary EV propulsion systems.
Whatever performance today’s asymmetric passive-rotor electric-machine systems can achieve, electric-machine physics dictates that retrofitting them with the SYNCHRO-SYM™ symmetric active-rotor architecture will double their performance versus cost.
SYNCHRO‑SYM™ EMS —The Ultimate EMS
The SYNCHRO-SYM™ Comparison Calculator will provide an AI-generated comparison report between your current EMS and a drop-in SYNCHRO-SYM replacement.
BEST ELECTRIC MACHINE →SYNCHRO-SYM™ KEEPS DELIVERING
Every EMS product purchase today—especially the constant wave of so-called advanced high-performance EMS designs—ultimately delivers another “same-old” asymmetric, passive-rotor EMS constrained by the classical limits of that architecture and packaging but claiming performance-to-price advantage through marketing hype and flashy visuals that merely insinuate a technology breakthrough.
The EMS of today relies on the same electromagnetically non-optimal asymmetric electric motor-generator system circuit and control architecture (A-EMS)—an “active-stator” with an independently-excited multiphase winding set (active winding set) that solely delivers the working power to the electromechanical power conversion process, paired with a “passive-rotor” using RE-PMs, slip-induction windings, field windings, or reluctance saliencies that cannot independently deliver additional working power but consumes the other half of motor size, loss, and cost in cascade with the active stator, and glued together by a disparate, estimation-dependent, high harmonic content, compensatory field-oriented control (FOC) derivative, enable by prevailing electronic technologies—performance-to-price distinction relies on unfairly exploiting the design specification or re-engineering the empirical selection of legacy packaging techniques without allowing the same opportunity to contestants—physics dictates similar nominal performance-to-price results if packaging and design specifications are equally applied.
The EMS of today is built from essential but separately distinct components—electric motor, electronic controller, and if needed for useful peak torque production, high maintenance and lossy gearbox—all from different technical disciplines without shared understanding—often from different manufacturing sources with so-called “integration” amounting to little more than adjacent placement. Depending on which component is referenced, the compounded losses, costs, and size of these essential components are often overlooked in the real-world “system of systems” performance—leaving EMS customers misled and frustrated. Note: The gearbox reduces the amount of costly rare-earth permanent magnets (RE-PM) by enabling a smaller, higher speed motor to achieve reasonable application torque.
A SYNCHRO‑SYM™ product purchase—provides the fundamental symmetric, active rotor circuit and control architecture and foundational study for all—delivering superior performance-to-price advantage over all other asymmetric, passive-rotor circuit and control architectures by applying real innovation grounded in the principles of physics instead of marketing spin.
Our patented SYNCHRO-SYM™ establishes the commercially realizable form of the electromagnetically optimal symmetric electric motor-generator system circuit and control architecture (S-EMS): a brushless, dual-active power-conversion system in which both stator and rotor actively participate in electromechanical energy conversion with the same motor size, loss, and cost as the A-EMS. This architecture is enabled exclusively through our patented, integrally unified, solid-state, brushless, sensorless, pure-sinusoidal Real-Time Emulation Control (BRTEC), made practical by the performance advancements of modern power electronics and computational control. When evaluated at equivalent design voltage, excitation frequency, rated torque, synchronous speed, and package constraints, electromagnetic symmetry yields approximately 2× nominal performance-to-price and up to 8× peak torque capability relative to contemporary passive-rotor asymmetric systems (A-EMS) with similar package footprint.
Our patented SYNCHRO‑SYM is an integrally unified circuit and control system—never sold separately—always factoring the added losses, costs, and size of every system part for real world performance, including BRTEC.
Our patented Brushless Real Time Emulation Control (BRTEC™)—compact solid-state, quantum level stabilization with inherent symmetrically soft switch, pure sinusoidal, direct AC-to-AC power conversion at half the current rating; no bulky, costly DC link stage—inherently providing full rotor and stator metrics in real-time for superior operation and integrally unified into the frame for another level of EMS power-density. Highly adaptable, BRTEC conveniently enables an ultra-high-performance, symmetrically bi-directional, multiphase, isolated electric vehicle (EV) micro-distribution bus and battery recharger—doubling the performance-to-price advantage of WBG semiconductors.
A SYNCHRO‑SYM™ product purchase—provides the only commercially practical symmetric, active rotor electric motor-generator system architecture (S-EMS) product for a truly new era in low-carbon footprint electrification.
As the foundational theoretical framework for electric machine systems, the S-EMS architecture is not new; rather, it fundamentally defines the governing electromagnetic relationships, circuit and control structures, packaging constraints, and thermal limits of the electromechanical energy-conversion process. Asymmetric electric machine systems can be understood as practical, de-optimized derivatives of this symmetric framework, in which actively controlled rotor excitation symmetry is replaced by passive-rotor asymmetry enabled by less stringent field-oriented estimation and control—methods consistent with the electronic control capabilities available during their commercial development. Accordingly, over a half-century of classical laboratory research already validated 2× to 8× performance-to-price and torque of the original A-EMS package retrofitted with the S-EMS circuit and control technology (e.g., active rotor + BRTEC)—reducing losses, constraining core saturation, eliminating the need for rare-earth magnets, slashing strategic materials, such as copper or aluminum, per kW, and realistically enabling maintenance-free, tunable, gearless electromagnetic transmission & electromagnetic braking.
Note: Never realizing the practical BRTEC invention (until SYNCHRO‑SYM™) to brushlessly propagate speed-synchronized multiphase power to the rotor—constrained by the limitations of prevailing control technologies—the higher performing S-EMS was sidelined by the timely invention of the high-energy product RE-PM (circa 1980) for a practical RE-PM A-EMS with unforeseen environmental, unsustainable, and geopolitical consequences of its widespread adoption. Despite SYNCHRO-SYM™ already demonstrating a practical maintenance-free, brushless S-EMS, the industry remains blind to its existence, because SYNCHRO-SYM™ is repeatedly mistaken for familiar A-EMS variants with legacy packaging techniques and geometries: wound-rotor doubly-fed “induction” machines with passive multiphase rotor windings, brushless doubly-fed designs with unlike pole-pairs, or so-called ‘symmetric’ A-EMS (e.g., DeepDrive) that rely on nothing more than legacy, geometric dual-rotor or dual-stator symmetry with the expanded package size, loss, and cost of two highly integrated motors.
SYNCHRO‑SYM is a drop-in replacement to today’s A-EMS—including any in-wheel EMS—but uniquely with more power, more torque, more efficiency, and no rare-earth permanent magnets.
SYNCHRO-SYM™ conforms to the evolving EV and aerospace packaging frameworks developed for today’s A-EMS—frameworks that have largely defined the performance ceiling of A-EMS architectures—eliminating mechanical re-engineering while delivering a step change in performance through its active-rotor symmetric electromagnetic architecture.
SYNCHRO‑SYM is a performance upgrade to today’s advanced, externally excited field-wound synchronous A-EMS—providing the same RE-PM-free benefits but with double the electromagnetic performance.
SYNCHRO-SYM provides superior performance in rare-earth-free, low-speed, high-power direct-drive applications—operating regimes historically constrained to rare-earth permanent-magnet machines due to the torque-density, efficiency, and core saturation limitations of conventional passive-rotor alternatives.
SYNCHRO‑SYM is the realistic software-defined EMS, as only possible with the symmetry of an integral active rotor electric motor-generator circuit and integrally-unified control technology—the so-called software-defined EMS of others is built with the deoptimized asymmetry of separate, adjacently mounted, passive rotor circuit and externally mounted control components.
SYNCHRO‑SYM will be the future’s EMS of choice—even enabling the practical reality of superconductor packaging techniques that establish air-gap flux density beyond the supporting limits of core material.
“While all others continue the hard work of optimizing legacy EMS packaging geometry using century old asymmetric circuit and control technology with a passive rotor of slip-induction, rare-earth permanent magnets, reluctance saliencies, or DC field windings,” said Frederick W. Klatt, CTO of BEM, “Only BEM did the hard work of researching, developing, engineering, and manufacturing the optimum symmetric circuit and control technology with an active rotor, called SYNCHRO-SYMTM, that uses the same optimized A-EMS package geometry yet doubles the nominal power rating and halves the cost and loss per kW with both rotor and stator working together.”
A SYNCHRO-SYM product purchase—provides quick, secure inhouse, additive manufacturing by our patented MOTORPRINTER™ 3D Printing method, called MOTORPRINTER™—reprogrammed by BEM’s computer aided design tool for implementing the S-EMS architecture (BEM-CAD™)—all other EMS manufacturing relies on the same-old subtractive manufacturing methods, perhaps supplemented with robotic automation.
MOTORPRINTER enables just-in-time customization – Allows rapid, just-in-time adaptation to specific customer needs.
MOTORPRINTER enables proprietary SYNCHRO-SYM™ direct cooling with unmatched thermal management for superior performance.
MOTORPRINTER enables system advantages – Delivers higher reliability, significantly lower cost, greater power density, and higher specific power compared to conventional methods.
MOTORPRINTER enables advanced materials integration – Enables practical use of exotic, high-performance core materials for high and low frequency machines, such as thin amorphous or nano-crystalline ribbon, previously impractical in motor manufacturing, while eliminating the price premium typically associated with complex axial-flux electromechanical structures.
MOTORPRINTER enables non-smokestack manufacturing – low tool wear, low waste additive manufacturing without heavy capitalization in factory footprint, utility infrastructure, and change-over tooling for assembly line manufacturing.
MOTORPRINTER enables scalable, portable manufacturing footprint – Conventional manufacturing facilities are designed and capitalized for a forecasted production volume, which does not cost-effectively or timely scale to actual sales volume.
MOTORPRINTER enables rapid deployment and distributed domestic production scaling through modular replication of its compact, process-ready, containerized, automated programmable additive-manufacturing platform.
A SYNCHRO-SYM product purchase—means working with our lean, expert-driven team culture that prioritizes customer satisfaction, engineering excellence and genuine innovation—uniquely delivering a truly groundbreaking S-EMS solution. Unlike today’s A-EMS product purchase that prioritizes flashy branding and marketing spin but delivers the same-old A-EMS solution as new and innovated.
Only BEM established a higher-purpose commercialization framework to bring the next-generation brushless axial-flux SYNCHRO-SYM™ to market—targeting the $100B EV propulsion market—correctly including the complete EMS system cost, not just the motor-generator. BEM also plans to expand into the $200B industrial EMS market.
SYNCHRO‑SYM™ represents one of the single biggest opportunities to accelerate our clean, efficient, and sustainable energy future—Both the battery and the EMS account for 30–40% of the EV’s total cost-of-goods with an equally significant impact on performance, price, and sustainability. With 85% of EVs still relying on rare-earth permanent magnets (RE-PMs) EMS, switching to SYNCHRO-SYM™ delivers a step-change-improvement in efficiency, power density, and cost.
SYNCHRO‑SYM™ offers significantly higher-performance and an ethically sound alternative to the RE-PM-based A-EMS—anecdotally regarded by practitioners as the best EMS but unethically monopolized by geopolitical adversaries causing alarming environmental, labor, supply chain, and geopolitical risks. By eliminating the RE-PM array from the EMS with a better performing solution, SYNCHRO‑SYM™ redirects a majority of these scarce materials to other strategic applications and mitigates the sustainability of global mineable reserves.
SYNCHRO‑SYM™ delivers the industry’s lowest-carbon-footprint EMS—uniting magnet-free SYNCHRO-SYM™’s unmatched efficiency, power density, and lowest cost with MOTORPRINTER™’s additive manufacturing.
Transformed the foundational study and pinnacle of electric motor-generator technology into practical reality with invention, research, development, and radial-flux SYNCHRO‑SYM™ prototypes for S-EMS validation—the active-rotor S-EMS delivers 2× to 8× the performance-to-price and torque of any passive-rotor A-EMS package according to over a half-century of classical laboratory research.
Engineered a validated, scalable working design template for retrofitting the radial-flux product line of a major industrial motor division, ultimately leading to a $4M contract negotiation.
Speaking engagements and authored articles with NREL and IEEE—all providing peer-review validation.
Orchestrated empirical MOTORPRINTER validation studies with fiber laser and amorphous metal companies.
Patented a portfolio of technologies covering S-EMS architecture and 3D Printing—vetted, peer review validation.
Developed Axial-Flux SYNCHRO‑SYM™ CAD Tools (i.e., BEM-CAD™) for programmable MOTORPRINTER™ production of our next-generation axial-flux designs—quick, just-in-time manufacture of any customer power rating request.
Developed the modular maintenance-free BRTEC design architecture with compact solid-state Magnetic Sharing™, inherent soft switching, pure sinusoidal, and symmetrically bidirectional, direct AC-To-AC power conditioning with a scalable power module—no bulky and inefficient DC Link Stage with high harmonic content excitation—quick BRTEC retrofit to any customer power rating request.
Developed a convenient means to stack SYNCHRO-SYMs lengthwise for incremental increases in power rating, redundancy, and resiliency as is only possible with integrally self-contained SYNCHRO-SYMs.
Developed “How Do You Know SYNCHRO-SYM Outperforms the EMS of all others?“—a set of simple, physics-based rules for our customers to equitably compare our competitors’ EMS performance-to-price claims, cutting through the marketing spin—backed-up by BEM-CAD™.
SYNCHRO-SYM™ is the only commercially practical electric motor-generator system (EMS) that replaces today’s passive-rotor architectures with a fully active-rotor design—achieving optimal electromagnetic symmetry within the same package footprint as today’s EMS—reliant on the electromagnetic asymmetry of induction windings, reluctance saliencies, permanent magnets, or field windings.
SYNCHRO-SYM™ enables both the stator and rotor to contribute working power to energy conversion and eliminates reliance on exotic RE-PMs or costly Halbach magnet arrangements—delivering breakthrough performance at the world’s lowest cost per unit of power, including RE-PM-free direct-drive systems or wind-turbine applications.
Employing a time-proven axial-flux form factor, engineered using BEM-CAD™, and securely manufactured in-house with BEM’s rapid, low waste, just-in-time, reprogrammable MOTORPRINTER™, SYNCHRO-SYM™ is now available for purchase at the customer’s required performance point and minimum purchase volume with a transparent, well-defined price and delivery schedule—clearly distinguishing it from today’s asymmetric EMS competitors that rely on creative marketing, offshore manufacturing, and opaque price-delivery negotiations.
SYNCHRO-SYM achieves a compelling combination of price, performance, and delivery schedule that consistently surpasses and underprices imported advanced rare-earth permanent-magnet asymmetric electric machine systems (RE-PM A-EMS), including the ultra-low-cost Alibaba benchmark. The result is a domestically manufactured propulsion solution that eliminates rare-earth dependence while strengthening U.S. manufacturing competitiveness, supply-chain resilience, and clean-energy security.
