ZF has secured its first major customer order for its next-generation eRE+ range extender technology, with Chinese automaker Leapmotor set to integrate the system into a version of its upcoming premium SUV, the D19, beginning in 2026. This milestone highlights growing global demand for advanced range-extender solutions, especially across China and North America.
In typical generator-mode operation, the eRE+ uses a combustion engine to drive the electric motor, charge the high-voltage battery, and significantly extend driving range. Going beyond standard range extenders, ZF’s eRE+ also enables switchable all-wheel drive via the front axle and delivers up to 200 kW of additional drive power, giving drivers enhanced performance for overtaking and dynamic driving situations.
Sebastian Schmitt, Head of ZF’s Electrified Drive Technologies division, noted that global momentum for REEVs (range-extended electric vehicles) is accelerating. In China, these vehicles are recognized as “new energy vehicles,” while in the U.S., they are increasingly preferred for their independence from charging infrastructure.
Timo Meisel, Senior Vice President for Electrified Powertrain Technology, Asia Pacific, added that ZF’s proactive investment in flexible range-extender solutions and localized production has directly contributed to securing the Leapmotor partnership.
eRE+: Advanced, Dual-Function Range Extender with Direct Drive
The Leapmotor D19 will be the first model to benefit from ZF’s upgraded eRE+ architecture, which builds on the foundational eRE system. Like its predecessor, the eRE+ integrates an electric motor, inverter, smart software, and planetary gearbox. However, the addition of an intelligent clutch and differential allows the system to function as a secondary drive unit, eliminating the need for additional hardware.
Key performance highlights for the D19 include:
90 kW generator output
200 kW peak drive output
More than 1,000 km total driving range
The combustion engine required for operation is supplied by the OEM, not ZF.
Boosting EV Adoption & Supporting Climate Goals
By operating the engine only in its most efficient range, ZF’s eRE+ ensures reduced fuel consumption and lower CO₂ emissions. According to ZF CEO Mathias Miedreich, range-extender technologies serve as a bridge between current consumer expectations and the fully electric future—enhancing EV acceptance and accelerating market penetration.
With low integration costs, shorter development cycles, and simplified supply chains, the technology is especially attractive for OEMs building EV-focused platforms. Miedreich emphasized that approving range-extender technology beyond 2035 could reinforce EU climate goals by offering consumers extended range, flexibility, and a smoother transition to full electrification.
