MAHLE Unveils Range Extender System for Electric Trucks

MAHLE has introduced a new range extender system for battery-electric heavy trucks, designed to increase vehicle range, reduce battery size and improve operational flexibility for commercial fleet operators. The technology will make its world premiere at IAA Transportation 2026 in Hanover ( September 15 - 20 ), Germany, alongside additional electrification and thermal management solutions for heavy commercial vehicles.

The company positions the system as a practical approach to accelerating the transition from diesel-powered trucks to battery-electric vehicles by addressing two major barriers to adoption: limited driving range and insufficient charging infrastructure. Alongside battery-electric technologies, MAHLE also presented developments supporting renewable fuels and hydrogen applications as part of a broader strategy for reducing emissions in road transport.

Range extender system increases vehicle flexibility
The new range extender system functions as an autonomous power generation unit that supplements the truck's battery when additional energy is required. Instead of continuously operating, the internal combustion engine activates only when necessary to recharge the battery and maintain vehicle operation during longer journeys or demanding operating conditions.

At the core of the system is a high-voltage generator delivering a continuous output of 110 kW and peak power of up to 130 kW. Driven by a compact combustion engine, the generator supplies electrical power directly to the vehicle's electric drivetrain.

MAHLE developed the generator with an advanced oil-cooling system, achieving a power density exceeding 7 kW/kg while reducing weight and simplifying system integration.

Modular architecture enables integration into existing electric truck platforms
The complete range extender package combines the generator, combustion engine, thermal and fluid management systems, fuel tank, AdBlue tank and exhaust aftertreatment into a compact modular unit. The system is designed to occupy the same installation space normally used by part of the battery pack, allowing integration into existing battery-electric truck platforms with minimal redesign.

Replacing approximately one-third of the battery capacity reduces rear axle load by around 400 kg and lowers total vehicle weight by approximately 600 kg.

According to MAHLE, the combined system enables total driving ranges exceeding 800 km, with approximately 400 km supplied by the battery and an additional 400 km provided through the range extender.

Thermal management supports heavy-duty operation
To maintain stable performance under demanding operating conditions, the system incorporates a thermal management package providing 48 kW of high-temperature cooling capacity and 15 kW of low-temperature cooling capacity.

The company states that, under real operating conditions, trucks equipped with the range extender can reduce carbon dioxide emissions by approximately 80% compared with conventional diesel-powered trucks. When operated using renewable fuels such as HVO100, the combustion engine is designed to achieve near-zero CO₂ emissions.

New engine components target efficiency and lower operating costs
Alongside the range extender, MAHLE introduced several new combustion engine components intended to improve efficiency while reducing operating expenses.

The company's new Power Cell Unit (PCU) is designed to provide higher performance, improved durability and greater efficiency. MAHLE also unveiled a redesigned oil management module integrating the oil filter, oil cooler and bypass valve into a single assembly.

Depending on the housing material selected, the module can reduce material costs by up to 20%, lower product carbon footprint by up to 50% and decrease component weight by as much as 25%. Both products are compatible with multiple powertrain architectures beyond the new range extender system.

Rare-earth-free electric motor debuts at IAA Transportation
MAHLE also presented a new Contactless Transmitter (MCT) electric motor developed for heavy commercial vehicle electric drive axles.

Unlike permanent magnet synchronous motors, the MCT design does not require rare earth magnets, eliminating the use of approximately 3 kg of rare earth materials per vehicle.

The motor delivers a peak output of 370 kW and torque exceeding 900 Nm at 3,900 rpm. According to MAHLE, it is approximately 10% lighter than comparable permanent magnet motors while offering improved efficiency across a wider operating range. The company reports motor efficiency of approximately 95% in the VECTO simulation cycle used for evaluating heavy commercial vehicle efficiency in Europe.

Electrification strategy expands across global commercial vehicle markets
MAHLE continues to expand its electrification portfolio across commercial vehicle applications, supplying electric drive systems, thermal management technologies and electrified auxiliary components.

The company reports annual production of approximately eight million electric drive systems and electrified auxiliary products. Between 2026 and 2029, more than 35 electrified passenger vehicle and commercial vehicle platforms are expected to enter production using MAHLE technologies.

Within Europe, MAHLE supplies components used across battery-electric and fuel-cell truck platforms and holds leading market positions in electric climate compressors while ranking among the major suppliers of electric pumps and cooling fans. The company is also increasing cooperation with Chinese commercial vehicle manufacturers expanding into European battery-electric truck markets.

Renewable fuels and hydrogen remain part of the decarbonization strategy
While electrification remains a major focus, MAHLE expects internal combustion engines to continue playing an important role in commercial transportation over the coming decade.

The company highlighted renewable fuels such as HVO100 biodiesel and bio-LNG as immediate options for reducing emissions from existing commercial vehicle fleets. Research activities at the MAHLE Global Biomobility Center in Brazil continue to support development of biofuel engines, multi-fuel powertrains and sustainable materials.

MAHLE is also participating in hydrogen engine and fuel cell development projects across Europe and Asia, viewing hydrogen as an important long-term component of commercial vehicle decarbonization.

Industry calls for infrastructure and regulatory alignment
During the announcement, MAHLE emphasized that broader deployment of battery-electric commercial vehicles depends on faster expansion of charging infrastructure, hydrogen refueling networks and supportive regulatory frameworks.

The company also advocated technology-neutral regulations that recognize battery-electric systems, hydrogen technologies, renewable fuels and range extender solutions as complementary pathways for reducing emissions in heavy commercial transport.

Additional Context:This section details technical specifications and competitive benchmarking not included in the original product announcement
Range extender systems are receiving renewed attention within the commercial vehicle industry as manufacturers seek practical solutions for long-haul battery-electric transport while charging infrastructure continues to develop. Unlike conventional plug-in hybrid powertrains, heavy-duty range extenders primarily operate as onboard electricity generators, allowing vehicles to retain electric propulsion while extending operational range.

Several commercial vehicle manufacturers and suppliers are pursuing similar approaches. Companies including Scania, Volvo Trucks, Cummins and ZF are developing or evaluating range-extending technologies, while alternative solutions such as hydrogen fuel cells and battery swapping are also being explored for long-distance freight applications. At the same time, permanent magnet-free electric motors are gaining interest across the industry because they reduce dependence on rare earth materials, helping manufacturers address supply chain risks and improve sustainability.

Edited by Sucithra Mani, Induportals editor – adapted by AI.

www.mahle.com