This paper presents the design of flywheel rotor prototypes developed to enhance rural energisation in sub-Saharan Africa. The flywheel rotors are made from locally available fibre and epoxy resin. The profiles were designed using novel shape profiles based on Berger. Porat and Stodola's designs and manufactured using locally available materials. One of the flywheel rotor profiles was tested on a rig with an Axial Flux Permanent Magnet Machine and it was able to store 227 kJ of energy. A life cycle cost analysis was performed to compare the energy costs between a lead acid battery system and a flywheel rotor system. It was realized that by integrating the flywheel system into Solar Home Systems, a cost saving of 37% per kWh for rural system installations would be achieved. (C) 2011 Elsevier Ltd. All rights reserved.