According to Smithsonian magazine (from the world’s largest research institute Smithsonian, under the U.S. government), Robert Sansone (17, from Fort Pierce, Florida, USA) is a “natural engineer,” creating everything from electronic hands to high-speed running shoes and a go-kart capable of reaching speeds over 113 km/h.
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 about the advantages and disadvantages of electric cars. The video explained: Most electric car 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/kg. In contrast, copper is priced at $7.83/kg.
“I have a passion for electric motors. I wanted to try designing a different type of engine using copper“, Sansone shared.
In the household appliance market, there is a type of electric motor with a copper core that generates a rotating magnetic field, without using rare earth materials. This motor is currently used for pumps and fans, but it is not powerful enough for use in 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 3-D printed plastic, copper wire, and steel rotor. This motor was tested using various meters to measure power and a laser speed gauge to determine the motor’s rotational speed.
Sansone’s design has 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 in the largest international high school STEM competition at the Regeneron International Science and Engineering Fair (ISEF) in 2022.
Sansone is waiting for his next testing phase before approaching automotive companies. He hopes that one day his engine 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 would use his prize money from ISEF to cover his college tuition.
Mr. Heath Hofmann – a professor of electrical and computer engineering at a university, who has many years of experience working on electric vehicles, including consulting for Tesla to develop control algorithms for propulsion motors – appreciates Sansone’s efforts, but noted that machinery is very complex and notoriously difficult to manufacture, which will be a barrier for Sansone’s invention.
Sansone agrees but says, “with new technologies (such as 3-D printing), it will be easier to make new motors in the future.”