Mahle is moving its range-extender technology for electric trucks from development toward vehicle testing, with the supplier confirming that prototype projects are underway with commercial vehicle manufacturers ahead of planned real-world road trials.
Mahle first announced the range-extender system in August ahead of IAA Transportation 2026, where the technology is now making its public debut. The company has not disclosed the manufacturers involved, the number of prototypes planned or when series production could begin.
Range Extender Targets More Than 800 Km
Mahle’s system combines a high-voltage generator with 110 kW of continuous power and 130 kW peak output with a compact internal combustion engine.
The generator, engine, thermal management system, fuel and AdBlue tanks, and exhaust aftertreatment are integrated into a single unit. The range extender replaces part of the battery capacity in an electric truck, while the vehicle’s wheels continue to be driven exclusively by electric motors.
According to Mahle, the system can eliminate around one-third of the original battery capacity. Despite adding the range-extender hardware, the company expects a correspondingly configured truck to be around 600 kilograms lighter.
Mahle says a vehicle designed around the system could achieve a total range of more than 800 kilometres, with approximately 400 kilometres supplied by the battery and another 400 kilometres provided by the range extender.
Addressing Heavy-Truck Charging Constraints
Mahle is positioning the range extender primarily as a solution for gaps in charging infrastructure for heavy commercial vehicles.
The technology could allow electric trucks to retain electric propulsion while using the onboard generator to provide additional energy for longer routes. However, the upcoming prototype tests will determine whether the projected benefits in range, weight and operating costs can be achieved under real-world fleet conditions.
Rare-Earth-Free Electric Motor
Mahle is also presenting its previously announced Contactless Transmitter (MCT) for electric drive axles in heavy commercial vehicles.
The motor does not use permanent magnets, eliminating the need for rare-earth elements. It delivers up to 370 kW of peak power and more than 900 Nm of torque.
Mahle states that the motor achieves 95% efficiency in the VECTO cycle.
The company also estimates that the design can eliminate up to three kilograms of rare-earth magnets per vehicle compared with a comparable permanently excited synchronous machine. The drive system can also be up to 10 kilograms lighter, according to Mahle.
Mahle Calls For Technology-Neutral Regulation
Mahle is using its IAA Transportation 2026 appearance to renew its call for technology-open regulatory frameworks for road freight.
The supplier argues that battery-electric drivetrains should be accompanied by other technologies, including range extenders, hydrogen and renewable fuels, as the road freight sector works to reduce emissions.
Mahle is also calling for changes to European CO₂ regulations for heavy commercial vehicles, arguing that a broader range of technologies should be considered in the transition to lower-emission transport.
