ZF has secured its first commercial order for the eRE+ range extender, a next-generation hybrid system set to launch in Leapmotor’s upcoming D19 premium SUV in 2026. The agreement marks a key step for ZF in expanding its hybrid powertrain footprint within China and highlights growing demand for range-extended electric vehicles.
Unlike conventional range extenders that operate only as generators, the eRE+ incorporates an intelligent clutch and differential, allowing the unit to directly power the vehicle when needed. This architecture enables switchable all-wheel drive functionality and performance boosts without requiring additional drive components, reducing development time and hardware complexity for automakers.
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For the D19 SUV, the system provides a 90 kW generator output and peak driving power of 200 kW. The setup combines an electric motor, inverter, software controls, planetary gearbox and intelligent clutch. Leapmotor’s integration of the system will enable the vehicle to exceed a driving range of 1,000 km while maintaining lower emissions.
Demand for range-extended EVs is rising in China and North America, where charging infrastructure gaps make hybridized solutions attractive. ZF said the eRE+ allows manufacturers to use smaller batteries while offering long-range capabilities, supporting cost efficiency and supply chain simplification. The range extender engine operates continuously in an optimal fuel-efficiency band, reducing CO₂ output compared with traditional internal combustion designs.
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ZF said the technology serves as a transition solution for markets moving toward full electrification. It complements policy trends in Europe aimed at cutting emissions while addressing real-world charging constraints.
