MAHLE Unveils Range Extender System and Thermal Management Module at IAA Mobility 2025

German automotive supplier MAHLE launched production-ready innovations for sustainable mobility at the IAA Mobility trade show in Munich on September 8, 2025, featuring a new range extender system capable of extending electric vehicle range to 1,350 km and a thermal management module that increases efficiency by up to 20 percent in cold conditions.

Range Extender Technology Addresses Range Anxiety

The company unveiled its new range extender system with an 85 kW rated continuous output, designed to alleviate consumer range anxiety and accelerate electric vehicle adoption. The system combines an 800V high-voltage generator with a compact internal combustion engine, achieving peak efficiency exceeding 97 percent and continuous power density over 50 kW per liter.

"Our products are not just visions. They are ready for series production and offer genuine solutions to genuine challenges faced by our customers," said Arnd Franz, Chairman of the MAHLE Management Board and CEO, addressing journalists at the trade show.

The range extender's internal combustion engine incorporates MAHLE's jet ignition combustion technology with turbocharging and Miller valve timing, delivering efficiency over 42 percent while maintaining quiet operation. The system enables cost-effective battery rightsizing and reduces charging times on longer trips.

Thermal Management Module Enhances Cold Weather Performance

MAHLE's new thermal management module addresses a key challenge for electric vehicles - range loss due to heating requirements in cold temperatures. The integrated system includes an air-conditioning compressor, heat exchanger, refrigerant pumps, sensors and valves in a compact unit, reducing the number of refrigerant pumps per vehicle from four to three.

The module's heat pump technology increases range by up to 20 percent compared to systems using electric heaters, with series production scheduled within the next two years. The system maintains compatibility with current R1234yf refrigerant standards while offering future-proof transition capabilities to R290 propane.

Ethanol-Compatible Engine Components Support Biofuel Transition

The company showcased specially developed engine components for ethanol operation, including pistons, piston pins, rings and valve sets optimized for ethanol requirements. These components enable up to 100 percent ethanol operation, potentially reducing CO2 emissions by up to 70 percent with E100 fuel based on sustainable bio-ethanol production.

Market Growth and Industry Context

The market for electric vehicles with range extenders is forecast to grow 15 percent annually through 2030, with particularly strong demand emerging in China. MAHLE's innovations align with the company's strategy of technological diversity to address climate protection while maintaining European competitiveness.

CEO Franz emphasized the strategic importance of the approach: "Europe needs technological diversity for climate protection, to strengthen its competitiveness and to safeguard employment in Europe".

MAHLE also presented a bionic radial blower for vehicle air conditioning systems, inspired by penguin flippers and developed using artificial intelligence. The component operates 4 decibels quieter than conventional designs while delivering 15 percent higher energy efficiency.

The company's charging infrastructure division, MAHLE chargeBIG, has installed several thousand charging points across Germany and France, with the latest generation available since summer 2025. The system includes what the company describes as the world's smallest wall box.

Founded in 1920, MAHLE is an international automotive supplier serving both passenger car and commercial vehicle sectors. The Stuttgart-based company generated sales of €11.7 billion in 2024 with approximately 68,000 employees across 135 production locations and 11 technology centers in 28 countries. Today, one in every two vehicles globally contains MAHLE components.