Robert Sansone’s research may pave the way for sustainable electric vehicle production without the need for rare earth magnets, which are costly and environmentally harmful.
According to Smithsonian magazine (part of the largest research institution in the world, under the U.S. government), Robert Sansone, a 17-year-old from Fort Pierce, Florida, is described as a “natural engineer.” He has invented everything from an electronic hand to high-speed running shoes and a go-kart capable of exceeding speeds of 113 km/h.
Robert Sansone with his new motor – (Photo: SOCIETY FOR SCIENCE)
This “inventor” estimates that he has completed at least 60 engineering projects in his spare time outside of school.
A few years ago, Sansone watched a video discussing the advantages and disadvantages of electric cars. The video explained that most electric vehicle motors require magnets made from rare earth elements, which can be costly both financially and environmentally to extract. The necessary rare earth materials can cost hundreds of USD per kilogram, while copper is priced at $7.83 per kilogram.
“I have a passion for electric motors. I wanted to try designing a different type of motor using copper,” Sansone shared.
In the consumer appliance market, there is a type of electric motor with a copper core that generates a rotating magnetic field, not using rare earth materials. This motor is currently used for pumps and fans, but it is not powerful enough for electric vehicles. Therefore, Sansone began brainstorming ways to improve its performance.
Over the course of a year, Sansone invented a copper core electric motor that generates a rotating magnetic field and has higher efficiency than existing motors. The prototype is made from 3D-printed plastic, copper wire, and a steel rotor. The motor was tested using various gauges to measure power and a laser speedometer to determine the motor’s rotation speed.
Sansone’s design includes other components, but he cannot disclose any further details as he hopes to patent this technology in the future.
Sansone’s product earned him first place and a $75,000 prize at the largest international high school STEM competition at the Regeneron International Science and Engineering Fair (ISEF) 2022.
Sansone is awaiting the next stage of testing before approaching automotive companies. He hopes that one day his motor will be the chosen design for electric vehicles.
As a senior at Fort Pierce Central High School, Sansone dreams of attending the Massachusetts Institute of Technology (MIT). He stated that he intends to use his prize money from ISEF to cover his college tuition.
Heath Hofmann, a professor of electrical and computer engineering at a university with many years of experience in electric vehicles, including consulting for Tesla on developing control algorithms for propulsion motors, praised Sansone’s efforts. However, he noted that machinery is very complex and notoriously difficult to produce, which could pose a barrier to Sansone’s invention.
Sansone agrees but adds: “With new technologies (such as 3-D printing), it will be easier to produce new motors in the future.”
