This year, Mahle presented several products at IAA Mobility in Munich that are intended to steer the company further toward electrification and other sustainable drive solutions. Arnd Franz, Chairman of the Mahle Group Management Board and CEO, emphasized that the lineup presented consists of products that are ripe for serial production. Among the exhibited products is, among other things, a new Range Extender system with a high-voltage generator as well as a new diagnostic tool for drive batteries.
Mahle Range Extender
The Range Extender is intended to extend the range of battery electric vehicles to
up to 1,350 km. The Range Extender technology combines electric motors with established internal combustion engines. In this way, according to Mahle, the widespread range anxiety regarding electric vehicles should be reduced. The high-voltage generator achieves a peak efficiency of over 97 percent. The efficiency of the combustion engine is 42 percent and was developed for use with biofuels.
Technical specifications for the Mahle Range Extender:
- Maximum range on a single battery charge: depending on vehicle and battery size up to 1,350 km (WLTP)
- Rated continuous power: 85 kW
- System voltage: 800 volts
High-voltage generator:
- Peak efficiency: over 97 percent
- Continuous power density: over 50 kW/Liter
- Permanent-magnet electric machine with fully integrated cooling concept
- Direct rotor cooling reduces the need for rare earths in permanent magnets
Combustion engine:
- Efficiency: over 42 percent
- Mahle Jet-Ignition combustion technology and turbocharging
- Developed for use with biofuels
Mahle Drive Battery Diagnostic Tool “E-HEALTH Charge”
For the aftermarket, Mahle presents its diagnostic tool “E-HEALTH Charge.” The device is designed to determine the state of the high-voltage battery of an electric vehicle in 15 minutes, independent of the manufacturer. The tool is integrated into the mobile
charging station “E-Charge 20.” It charges the vehicle while the diagnosis runs. The diagnosis is supplemented with data from the OBD port. Benjamin Haas, Mahle's spokesperson, emphasised that, in light of the changes in the automotive industry, it is even more important for the company to support independent repair shops as best as possible and to prepare them for the future.
Mahle also presents the success of its charging station “MAHLE chargeBIG.” In Germany and France, several thousand such charging points have already been installed. The new product generation has been available since summer 2025.
