MAHLE is strengthening its electrification strategy with the introduction of a new range extender system for battery-electric heavy trucks, aimed at accelerating the transition from conventional diesel-powered commercial vehicles to electric mobility.
The new solution is designed to combine the environmental benefits of battery-electric drivetrains with the extended driving range and operational flexibility traditionally associated with internal combustion engines. By addressing range limitations and reducing the total cost of ownership, the technology is expected to support wider adoption of battery-electric trucks in the commercial transport sector while encouraging investment in sustainable freight mobility.
The company said range extender-equipped battery-electric trucks can also help manufacturers meet increasingly stringent European carbon dioxide fleet emission targets.
MAHLE, which is among Europe’s leading suppliers of electrification technologies for commercial vehicles, is also expanding its presence among Chinese truck manufacturers as they increase the introduction of battery-electric commercial vehicles into the European market.
Speaking at the company’s technology event in Stuttgart, Arnd Franz, Chairman of the Group Management Board and CEO of MAHLE, said the company is focused on driving future growth through production-ready electrification technologies and high-performance solutions.
At IAA Transportation 2026, scheduled to be held in Hanover from September 15 to 20, MAHLE will showcase the new range extender system as a world premiere under the theme “Electrified. Efficient. Economical.”
In addition to its latest range extender technology, the company will exhibit a portfolio of high-efficiency solutions for battery-electric and hybrid commercial vehicles, along with technologies that support the use of renewable fuels as part of efforts to decarbonise the road transport sector.
Forwarders and fleet operators face the challenge of making their business more climate-friendly despite steadily growing pressure on costs, without jeopardizing their economic viability or competitiveness. In this sector, the main obstacles to the growth of e-mobility are still the inadequate charging infrastructure for commercial vehicles in many regions and the limited ranges of battery-electric trucks. Flexibility and reliability are the key factors for business success in this sector. “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,” said Arnd Franz. “This is what we will be demonstrating to our customers, international vehicle manufacturers, and fleet operators at this year’s IAA Transportation.”
MAHLE will unveil its new range extender system for heavy battery-electric trucks at IAA Transportation 2026 in Hanover. Designed as an intelligent backup power solution, the system combines a compact internal combustion engine with a high-voltage generator delivering 110 kW continuous and 130 kW peak output, significantly extending the driving range of electric trucks while reducing dependence on charging infrastructure.
The self-contained unit integrates the generator, engine, thermal management, fuel tank, AdBlue tank, and exhaust after-treatment into a compact package that fits into the existing battery space of a battery-electric truck. By replacing about one-third of the battery pack, it reduces vehicle weight by around 600 kg while enabling a total driving range of over 800 km—approximately 400 km on battery power and another 400 km using the range extender.
MAHLE says the system can reduce CO₂ emissions by around 80% compared to conventional diesel trucks in real-world operation. When powered by renewable fuels such as HVO100 biodiesel, the range extender can achieve near-zero CO₂ emissions.
The system also features an advanced thermal management setup and newly developed engine components, including an improved Power Cell Unit (PCU) and oil management module, designed to enhance efficiency, lower operating costs, reduce weight, and extend service life.
According to Dr. Marco Warth, Vice President of MAHLE Corporate Research and Advanced Engineering, the range extender addresses one of the biggest barriers to electric truck adoption by ensuring uninterrupted operations even when charging infrastructure is unavailable or congested, thereby improving fleet reliability and operational flexibility.
MAHLE will debut its new magnet-free MCT (MAHLE Contactless Transmitter) electric motor for heavy commercial vehicles at IAA Transportation 2026. Free from rare earth elements, the motor is 10% lighter than conventional permanent magnet motors, delivers 370 kW of peak power, over 900 Nm of torque, and achieves around 95% efficiency in the EU’s VECTO cycle.
The company also highlighted its strong position in commercial vehicle electrification, supplying around 8 million electric drive systems annually and supporting more than 35 electrified vehicle platforms between 2026 and 2029. While expanding its electrification portfolio, MAHLE believes renewable fuels and hydrogen will remain essential for decarbonising heavy transport, as internal combustion engines are expected to continue dominating the commercial vehicle market through 2035. The company has called for technology-neutral regulations, improved charging and hydrogen infrastructure, and coordinated policy support to accelerate the transition to low-carbon road transport.
