<p dir="ltr">There is a growing demand for lower-cost, lighter-weight, and more compact electric ma-<br>chines used for vehicle propulsion. In this research, a dual-rotor inert-core machine (ICM) is<br>considered to meet this demand. In the ICM, permanent-magnet-based Halbach arrays are<br>placed on inner and outer rotating structures. This enables one to eliminate magnetic steels<br>used in the stator and rotor of traditional electric machinery. In addition, a stator structure<br>that leverages a thermal plastic is proposed that facilitates straightforward active cooling<br>of phase windings, which greatly increases current density. To support the multi-objective<br>design of the ICM, a multi-physics toolbox has been developed. Within the toolbox, electro-<br>magnetic performance is predicted using a method-of-moments-based field solver. Thermal<br>performance is assessed using a thermal equivalent circuit that includes conductive heat<br>transfer from stator windings to the surrounding environment as well as convective heat<br>transfer to moving fluids. The structural integrity of the stator is assessed using analytical<br>expressions to predict stress from material properties, geometry, and applied external forces.<br>Calculated loss of proposed designs includes those of the stator windings as well as those<br>required for active cooling. Several optimization studies have been conducted to evaluate the<br>performance of the ICM under an expected electric vehicle driving cycle. From the studies,<br>Pareto-optimal fronts are obtained and used to explore the impact of alternative cooling<br>strategies on volumetric power density.</p>