Robert Sansone, a 17-year-old student, has conducted research that could revolutionize the electric car industry by enabling sustainable production without relying on rare earth magnets, which are both costly and environmentally damaging.

As reported by Smithsonian magazine, part of the world’s largest research institution under the US Government, Sansone hails from Fort Pierce, Florida, and is described as a “born engineer.” His inventions range from electronic hands to high-speed running shoes and a go-kart capable of reaching over 113 km/h.

Robert Sansone with his new engine – (Photo: SOCIETY FOR SCIENCE)

This young inventor estimates he has completed at least 60 engineering projects in his spare time outside of school.

A few years back, Sansone viewed a video discussing the pros and cons of electric cars. The video highlighted that most electric car motors depend on magnets made from rare earth elements, which are expensive and environmentally unfriendly to extract. Rare earth materials can cost hundreds of dollars 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 explained.

In the home appliance market, there exists a type of copper core resistor motor that generates a rotating magnetic field without using rare earth materials. However, this motor, typically used for pumps and fans, is not powerful enough for electric vehicles. Thus, Sansone began brainstorming ways to enhance its performance.

After a year of work, Sansone invented a more efficient copper core resistor motor that creates a rotating magnetic field. His prototype, made from 3D printed plastic, copper wire, and a steel rotor, was tested using various meters to measure power and a laser tachometer to determine rotational speed.

Sansone’s design includes additional components, but he is withholding further details as he hopes to patent the technology.

His innovative motor earned him first place and a $75,000 prize at the 2022 Regeneron International Science and Engineering Fair (ISEF), the world’s largest international high school STEM competition.

Sansone is awaiting the next phase of testing before approaching automotive companies. He hopes that his motor will eventually become the preferred design for electric vehicles.

A senior at Fort Pierce Central High School, Sansone dreams of attending the Massachusetts Institute of Technology (MIT) and plans to use his ISEF prize money to help pay for college tuition.

Heath Hofmann, a professor of electrical and computer engineering who has extensive experience with electric vehicles, including consulting for Tesla, praised Sansone’s efforts. However, he noted that the complexity and manufacturing challenges of such machines could pose significant barriers to the young inventor’s success.