Induction machine rotor and method of making

A method of forming an electric machine for powering an electric vehicle, the electric machine having a rotor assembly configured to rotate relative to a stator to drive a rotor shaft and at least one drive wheel of the electric vehicle, the method comprising:

• providing a rotor core having a core body that defines a plurality of circumferentially arranged bar passages including a plurality of first bar passages and a plurality of second bar passages;
• inserting a first bar assembly into the plurality of first bar passages, the first bar assembly having a plurality of first bars, each of the first bars having a first elongated blade portion and a first end body portion;
• inserting a second bar assembly into the plurality of second bar passages, the second bar assembly having a plurality of second bars, each of the second bars having a second elongated blade portion and a second end body portion, wherein the first bars and the second bars are alternately received at the respective plurality of first bar passages and second bar passages in the core body;
• joining adjacent second elongated blades and first end body portions to create an electrically conductive first end ring;
• and
• joining adjacent first elongated blades and second end body portions to create an electrically conducting second end ring.