MAHLE has introduced a new range extender system for heavy battery-electric trucks to support the transition from diesel-powered commercial vehicles to electric mobility. The Stuttgart-based automotive component supplier said the technology combines the sustainability of electric drive systems with the flexibility and range of an internal combustion engine.

The system is designed to help fleet operators overcome challenges such as limited charging infrastructure and range constraints while reducing total cost of ownership over the vehicle life cycle. MAHLE will showcase the technology as a world premiere at IAA Transportation 2026 in Hanover under the theme “Electrified. Efficient. Economical.”

“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.

The range extender features a high-voltage generator with a continuous output of 110 kW and peak output of up to 130 kW, powered by a compact internal combustion engine. The integrated unit combines the generator, engine, thermal management systems, fuel tank, AdBlue tank and exhaust gas treatment within a compact structure that can be integrated into existing battery-electric truck platforms.

By replacing around one-third of the battery capacity, the system reduces rear axle load by about 400 kg and overall vehicle weight by about 600 kg. A range extender-equipped electric truck can achieve a total range of more than 800 km, with approximately 400 km provided by the battery and the remaining 400 km by the range extender.

Under real-world conditions, MAHLE stated that the truck can deliver around 80% lower CO? emissions compared with conventional drive systems. When operated with renewable fuels such as advanced HVO100 biodiesel, the vehicle can achieve virtually zero CO? emissions.

MAHLE will also showcase its Contactless Transmitter (MCT) electric motor for heavy commercial vehicles at IAA Transportation. The motor eliminates the need for permanent magnets and rare earth elements, saving up to 3 kg of rare earth magnets per vehicle.

The MCT motor is 10 per cent lighter and more efficient than permanently excited electric motors, delivering a peak output of 370 kW and torque of more than 900 Nm. Its efficiency in the VECTO cycle is around 95 per cent.

MAHLE said it is expanding its electrification portfolio across commercial vehicles, including thermal management systems, electric fans, charging connection boxes, battery cooling plates and traction motors. The company works with more than 120 customers in the commercial vehicle and off-road sector and expects its commercial vehicle business to grow faster than the market over the next five years.

The company also highlighted the continued role of renewable fuels alongside electrification. MAHLE said sustainable fuels such as HVO100 and bio-LNG will remain important for reducing emissions from existing commercial vehicle fleets.

“Technological diversity will be crucial. Battery-electric vehicles, hydrogen and renewable fuels for internal combustion engines must be used together to reduce CO2 emissions,” said Arnd Franz, Chairman of the Group Management Board and CEO of MAHLE.