BorgWarner showcases new propulsion tech at IAA, India remains a key priority

Harry Husted, Chief Technology Officer (L) and Paul Farrell, Chief Strategy Officer, BorgWarner with the company's latest exhibits at the IAA Mobility 2025 show.

The US-headquartered Tier-1 propulsion systems major BorgWarner has showcased its latest innovations at the IAA Mobility 2025 show in Munich, with the company unveiling its range of e-torque and thermal management systems, propulsion drive units, EGR and boosting solutions for ICE, as well as five-in-one modules for hybrids and two-in-one modules for range extender applications.

The company’s latest technologies, developed leveraging its domain expertise across various geographies around the world, aim at creating a multi-powertrain competency, given the uncertainty in the offtake of EVs in certain markets, continued demand for ICE, as well as the rising demand for hybrid systems such as range extenders in others.

Speaking to *Autocar Professional* on the sidelines of IAA Mobility 2025, Paul Farrell, Chief Strategy Officer, BorgWarner, said, “If we look at the US market, it registered a 4% decline in overall vehicle volumes in H1, whereas Europe too was down nearly 3%. On the other hand, when it comes to the propulsion mix, while EV penetration is not moving ahead at the same pace as expected 2–3 years ago, it has continued to grow across the board. In H1 of 2025, EV penetration rates went up, to the tune of 40%, particularly in Europe and China.”

“Considering this evolution in propulsion technologies, we spent a major part of the last decade focusing on building the right product portfolio, and now, we are making sure to offer the right products to the right customers in the right regions. Thus, we have been balancing ICE, hybrid, and EV technologies within our portfolio, and are being resilient to manage the uncertainties,” Farrell added.

BorgWarner’s latest technologies keep this fundamental approach at their core and aim to offer propulsion solutions for a wide variety of vehicles and powertrain categories. According to Harry Husted, Chief Technology Officer, BorgWarner, “There is a lot that we have displayed this time around. We have products under e-torque management, propulsion drive units and power electronics, thermal management, and solutions such as cam-phase controllers that are aimed at making ICE vehicles more efficient.”

Latest Tech on Display

Within the e-torque management system, the company leveraged its capabilities to offer torque-vectoring disconnect, wherein the system helps the driver manage the instant torque on tap in an EV powertrain by splitting it from side to side. This unit is already in production with an automaker, and there are several more in the pipeline. It is becoming popular among EV OEMs.

BorgWarner also showcased its 5-in-1 drive unit targeted at hybrid vehicles, specifically those in China having a dedicated hybrid transmission. The system comprises a generator motor that connects with the engine, a traction motor and two separate inverters powering each of the motors, and a final gear drive that goes to the axle.

The company has integrated this complex system into a single module, which is currently in production. According to Husted, “It is a complex integration of electronics and mechanical systems, and is looking like a really good match for the China market.”

“We have also developed a 2-in-1 range extender module that is used as a generator as well as an inverter for range-extender vehicles. While this was developed by our China team, we see broader global applications for the 2-in-1 module as range extenders are seeing rising interest around the world,” Husted added.

In the domain of power modules, the company showcased its proprietary double-sided cooled package 800V inverter that makes it a compact power module. In its latest iteration, the system gets two power transistors in a single combined package, with high current ratings up to 400V and 800V.

Furthermore, in terms of boosting solutions for hybrids, the company showcased its e-turbo, which has been amalgamated with a high-speed electric machine that speeds up to over 200,000 rpm to give instantaneous torque boost to the vehicle. “This technology allows combustion-engine vehicles to gain dynamics that are very close to an EV,” he explained.

India Market a Priority

With a technology centre in Bengaluru that is focused on systems and software development, as well as local manufacturing facilities to cater to the demand from the Indian market, BorgWarner says India is on its top radar. “We have a strong presence in the India market, with a large technical centre in Bengaluru, alongside multiple production facilities. Therefore, India is an important market for BorgWarner, and we see the India market as an avenue of future growth,” said Farrell.

While it is navigating supply chain and geopolitical challenges with its general approach of manufacturing in the region, for the region, at a global level — where there is not a lot of growth — BorgWarner believes India is one market which offers better opportunities for growth.

“As electrification and other technologies come into the Indian market in a more significant way, they would probably move fairly quickly. Therefore, it is a question of how the Indian market evolves going forward,” said Farrell.

“We will ensure we are well positioned to support our customers in India, and while India is a priority for us even today, it will continue to be a growing priority for BorgWarner in the future,” Farrell signed off.