Commercial Powertrains: MAHLE Launches Range Extender and Magnet-Free Motor for Electric Trucks
Mitigating charging infrastructure constraints for commercial fleets, MAHLE partners with OEMs to integrate truck range extenders and rare-earth-free electric motors.
MAHLE has initiated development projects with commercial vehicle manufacturers to test its new range extender platform for heavy-duty battery-electric trucks. Unveiled at IAA Transportation 2026, the compact 110-kW high-voltage generator unit pairs with an internal combustion engine optimized for renewable fuels such as HVO100 or hydrogen.
For commercial fleet directors, logistics operations executives, and equipment buyers, the hybrid-electric architecture mitigates public charging delays by replacing one-third of standard battery capacity. The configuration lowers total vehicle weight by approximately 600 kg (1,320 lbs) while delivering a combined operating range exceeding 800 kilometers (500 miles).
Simultaneously, the supplier introduced its MAHLE Contactless Transmitter (MCT) e-motor for heavy-duty drive axles, which eliminates permanent magnets and rare-earth materials. According to MAHLE executive leadership, the 370-kW motor reduces drive system weight by 10 kg while achieving 95 percent efficiency under VECTO testing cycles.
