Automotive supplier MAHLE has introduced a new range extender system for heavy battery-electric trucks (BEVs), aiming to overcome range limitations and inadequate charging infrastructure while lowering operating costs and emissions for fleet operators.
The system, which will make its world premiere at IAA Transportation 2026 in Hanover, combines a compact internal combustion engine with a high-voltage generator delivering 110 kW continuous and 130 kW peak output. Designed as a compact modular unit, it integrates the generator, engine, thermal and fluid management systems, fuel tank and exhaust gas treatment into existing battery-electric truck platforms.
With the system replacing about one-third of the battery capacity, MAHLE said it reduces vehicle weight by around 600 kg while enabling a driving range of more than 800 km, around 400 km from the battery and another 400 km from the range extender.
“Our range extender is a smart ‘emergency power unit’ that is activated at precisely the right moment and significantly increases the range available,” said Dr. Marco Warth, Vice President, MAHLE Corporate Research and Advanced Engineering.
According to the company, trucks equipped with the system emit around 80% less CO₂ than conventional diesel trucks under real-world operating conditions. When operated with renewable fuels such as HVO100, the vehicle can achieve virtually zero CO₂ emissions.
MAHLE also unveiled its Contactless Transmitter (MCT) electric motor for heavy commercial vehicles. The motor does not use rare earth magnets, is 10% lighter and more efficient than comparable permanent magnet motors, delivers 370 kW peak power and more than 900 Nm of torque, while achieving around 95% efficiency in the EU’s VECTO cycle.
Highlighting the company’s growth strategy, Arnd Franz, Chairman of the Group Management Board and CEO of MAHLE, said, “With high-performance technologies and production-ready products for electrification we are aiming for further growth.”
On the challenges facing the transport sector, Franz said, “Time and energy are limited, valuable resources, especially in road transport business; only operators who work economically can survive. With electrification products, MAHLE can help make heavy trucks more efficient and flexible at the same time as reducing operating expenses.”
The company expects more than 35 electrified vehicle platforms based on MAHLE technologies to be launched between 2026 and 2029 and plans to expand its presence in Asia and among Chinese commercial vehicle manufacturers.
MAHLE also stressed that renewable fuels and hydrogen will remain critical to decarbonising road transport. “It is therefore clear that, in addition to electrification, supplies of sustainable fuels such as HVO100 and bio-LNG need to be massively expanded,” Franz said.
Calling for supportive policies, Franz urged regulators to adopt a technology-neutral approach. “Technological diversity will be crucial. Battery-electric vehicles, hydrogen and renewable fuels for internal combustion engines must be used together to reduce CO₂ emissions. Range extender systems should also be recognized pragmatically as a facilitator of electrification and taken into consideration in regulations,” he said.
Concluding, Franz said, “The transformation to climate-neutral road transport is technically feasible and can also be accomplished economically. However, this will only be possible if industry, government and customers act together in a coordinated way. At MAHLE, we contribute technological diversity and comprehensive systems competence to actively forge ahead with the transformation. The truck of the future will operate with MAHLE!”
