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MAHLE Presents Innovation That Promises to Transform Electric Cars With a Range of 1,350 km, Less Dependence on Large Batteries, and Efficiency in Low Temperatures
At the IAA Mobility 2025 in Munich, MAHLE unveiled a package of innovations that reinforces its strategy of technological diversity to tackle the challenges of global mobility. The German company introduced an autonomy extender capable of taking electric vehicles up to 1,350 km.
All of this with one battery charge, a new thermal management module that increases efficiency in low temperatures by up to 20%, and components for engines designed to operate on 100% ethanol.
The company bets on different electrification solutions, alternative fuels, and energy efficiency to reduce emissions and meet the demands of customers worldwide.
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Autonomy Extender: Up to 1,350 km in Electric Vehicles
The highlight of the presentation was the range-extending system, described by the company as the “engine of e-mobility.”
Compact and designed for integration into various platforms, the extender includes a highly efficient high-voltage generator powered by a small combustion engine.
According to MAHLE, this combination allows any battery electric vehicle to reach up to 1,350 km, according to the WLTP cycle, depending on the model and battery capacity.
The system has a continuous power output of 85 kW, a voltage of 800 volts, and peak efficiency greater than 97%.
The electric motor-generator uses integrated cooling to reduce the need for rare earths, making the design more sustainable.
The internal combustion engine, designed for biofuels, achieves efficiency greater than 42% and adopts Miller technology with a turbocharger, ensuring efficient performance and quiet operation.
For CEO Arnd Franz, the goal is clear: “Our products are not just visions. They are ready for mass production and provide genuine solutions to genuine challenges faced by our customers.”
Thermal Management Solves Range Loss
Another important advancement presented by MAHLE was the thermal management module. The component addresses one of the main problems of electric cars: the drop in autonomy in low temperatures.
The system integrates a high-efficiency heat pump, air conditioning compressor, heat exchanger, valves, and sensors into a single compact unit. This configuration ensures that all vehicle elements—from the battery to the electric motor—always operate at the ideal temperature, as well as ensuring comfort in the cabin.
As a result, the autonomy of electric cars can increase by up to 20% compared to systems that rely on electric heaters.
The solution reduces the number of cooling pumps from four to three and is prepared to operate with both R1234yf gas and propane (R290), considered more sustainable. Mass production is expected to start in the next two years.
Ethanol Engines and Immediate Decarbonization
In addition to solutions for purely electric vehicles, MAHLE also highlighted its work on sustainable internal combustion engines. The company presented components capable of operating on up to 100% ethanol (E100).
According to the company, the adoption of ethanol can reduce CO₂ emissions by up to 70% over the fuel’s lifecycle, provided it is produced sustainably. Pistons, valves, pins, and rings have received heat, wear, and corrosion-resistant materials, ensuring reliability and performance.
This approach allows the existing fleet to contribute to immediate emissions reduction without compromising performance. “Europe must now follow the other major global markets and allow competition among all technologies in its CO₂ regulation,” emphasized Franz, advocating for the role of ethanol and other alternative fuels.
Nature-Inspired: Bionic Blower
The company also surprised by showcasing a bionic radial blower for air conditioning systems, inspired by penguin flippers. The innovative design was developed with the help of artificial intelligence, which generated millions of possibilities before selecting the final prototype.
The result is a blower that is 15% more efficient and up to 60% quieter than conventional models, as well as taking up less space inside the vehicle. This gain is considered essential for electric cars, where every centimeter is contested by propulsion systems, batteries, and electronic components.
Smart and Inductive Charging
MAHLE’s chargeBIG division was also present at the fair with scalable charging solutions. The company has already installed thousands of points in Germany and in France and now offers the world’s smallest wallbox, as well as a mobile version that can be used at construction sites and events.
Another highlight was the inductive charging system. The technology, which eliminates cables, has already been recognized as a global standard by SAE International and ensures energy transmission efficiency above 92% under real-world conditions.
Artificial Intelligence and Efficient Maintenance
In the test drive area of the IAA, the company demonstrated how it uses artificial intelligence to individually control the air conditioning for each occupant in the car. It also presented the portable E-HEALTH Charge unit, capable of measuring the condition of the high-voltage battery in just 15 minutes.
Additionally, it took the Workshop Heroes van to the event, part of the Aftermarket business unit. The vehicle travels to workshops across Europe to demonstrate new maintenance and diagnostic tools from MAHLE, including system calibration, battery checks, and cooling services.
Technological Diversity Strategy
Under the motto “Efficiency in Motion,” MAHLE reaffirms its future vision based on technological diversity. This includes electrification with advanced battery and thermal management solutions, engines ready for alternative fuels such as ethanol and biofuels, as well as smart charging systems and scalable infrastructure.
For CEO Arnd Franz, this approach is essential not only for climate protection but also for competitiveness and preserving jobs in Europe. “Our customers expect quality, reliability, good value for money, and efficiency. And that’s what MAHLE delivers,” he said.
With a combination of sustainable and economically viable solutions, the German company aims to increase its global relevance and consolidate its position as a key supplier for the energy transition of the automotive industry.
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