Offshore wind is a cornerstone of global net-zero ambitions, with capacity targets soaring and turbines reaching unprecedented sizes of 20 MW or more. Yet, the fundamental drivetrain technologies powering these giants have remained largely static for nearly two decades. As turbines grow larger and supply chain complexities intensify, the need for more flexible, scalable, and regionally adaptable generator technology is undeniable.
GreenSpur is rising to this challenge, not by merely refining the status quo, but by introducing a fundamentally new approach. Their magnet-agnostic axial flux generator architecture offers scalability, efficiency, and crucial adaptability, providing a much-needed alternative for manufacturers and developers seeking resilience in a demanding market.
Most utility-scale turbines today rely on radial flux permanent magnet generators, often using powerful neodymium-based magnets. While effective, these designs face significant drawbacks:
GreenSpur's axial flux alternative offers a different path. Built from the ground up, this design achieves high torque density in a more compact, modular layout. Crucially, it is magnet-agnostic.
"Being magnet agnostic is not a philosophical position but a practical design choice," explains Jason Moody, Chairman of GreenSpur. "It allows optimisation around what matters most in a given context, whether that is cost, weight, sustainability or local sourcing". This flexibility means the generator can be optimized for lower-powered ferrites where readily available or tuned for high-grade neodymium where maximum power density is paramount, without altering the core design.
The technology isn't just theoretical. GreenSpur's platform has been independently validated by the UK's Offshore Renewable Energy (ORE) Catapult. An 18 MW system-level review confirmed the design meets critical industry requirements for mass, efficiency, and manufacturability, placing it in direct competition with market leaders.
Key design advantages include:
A core differentiator is the focus on practical production. The GreenSpur generator design features:
"Development took place in close consultation with suppliers to ensure manufacturability in existing facilities, or easy transfer to new ones," Moody highlights. This isn't an R&D prototype; it's engineered for industrial deployment, underpinning GreenSpur's strategy of enabling localized manufacturing through licensing.
GreenSpur's primary model involves licensing its design, IP, and simulation tools to OEMs and regional partners. This offers a fast route to scale, reduces capital intensity, and supports local content requirements. It also allows OEMs to trial alternative generator technologies without long-term manufacturing commitments.
However, recognizing the need to accelerate deployment, the company is pragmatically exploring limited manufacturing initiatives in certain regions to demonstrate capability or meet early market access needs, complementing the core licensing strategy. The approach is shaped by regional priorities – sustainability in Europe, local manufacturing in North America, power density and cost in Asia.
The technology is robustly protected by nine patent families, providing partners with a secure foundation for collaboration and co-development.
The offshore wind market is dynamic. After years favouring direct drive, geared drivetrains are being reconsidered for ultra-large turbines due to potential cost, packaging, and serviceability benefits. Axial flux machines are naturally well-suited to this trend, potentially achieving system efficiencies near 99% in geared configurations.
Simultaneously, demands for grid-forming capability, dispatchability, and integration with storage are growing. The modularity of GreenSpur's architecture allows it to adapt to these evolving system requirements where traditional generator topologies may be reaching their limits.
GreenSpur, part of the UK-listed clean tech group Time To ACT, embodies a long-term vision focused on supporting the energy transition technically and systemically. Despite market turbulence, the company has gained momentum through system validation and alignment with industrial decarbonization policies.
The team is actively engaging with turbine stakeholders to explore various generator configurations and design studies. A UK-based manufacturing initiative is also under consideration to support domestic production and national clean energy goals, complementing the global licensing model.
GreenSpur's generator technology is more than just hardware; it's a strategic response to a global wind sector demanding flexibility, scalability, supply chain resilience, and regional adaptability. As turbines continue to grow in scale and complexity, drivetrain innovation must keep pace. This adaptable, magnet-agnostic approach offers a compelling pathway, enabling OEMs to build what they need, where they need it, with fewer constraints.