The automotive supplier Mahle made a commitment to technological openness in the fight against climate change as part of its Media Tech Day in Stuttgart. The company positioned itself as a driving force for a broad technological approach to decarbonizing road transport – beyond a sole focus on battery-electric mobility. At the IAA Mobility 2025 in Munich, Mahle will showcase innovative solutions from September 9 to 14 from its strategic core areas of electrification, thermal management, and sustainable combustion.
Technological Openness as a Strategic Guide
Mahle views the current one-sided regulatory policy of the EU critically. CEO Arnd Franz called for a timely revision of the European CO2 regulations to include sustainable combustion technologies and climate-neutral fuels. For Mahle, it is clear: The path to effective climate protection does not lead through monotechnologies, but through a sensible combination of different drive forms – battery electric vehicles, hybrids, range extenders, and modern combustion engines with synthetic or biogenic fuels.
“The revision of CO2 regulation in Europe brooks no delay. Combustion engines powered by climate-neutral fuels must be recognized as part of the solution,” said Arnd Franz, Chairman of the Management Board and CEO of Mahle.
In the current regulatory situation, Mahle as a company sees itself forced to consider a halt to all expansion and replacement investments around the sustainable combustion engine in Europe. If the EU does not move on the combustion ban, such an investment stop would be the logical consequence. However, the company still intends to be globally present with solutions
for CO2 reduction – particularly in markets like China, where hybrid and range extender concepts are strongly growing. Forecasts predict that the share of electric vehicles with range extenders in the global production of electrified passenger cars and light commercial vehicles will grow by 15 percent annually by 2030.
Efficiency in Focus at the IAA Appearance
Under the fair motto “Efficiency³”, Mahle will present several innovations at the IAA Mobility 2025 that distinguish themselves through high energy efficiency, compact design, and systemic thinking. The supplier will showcase its latest developments in three areas:
- Range extender technology for greater range of battery-electric vehicles,
- a modular thermal management module with integrated heat pump,
- and new engine components for operation with ethanol.
Additionally, a bionic radial fan for vehicle air conditioning systems will be presented, setting new standards both acoustically and energetically. All exhibits exemplify Mahle's approach to making electromobility more practical and sustainable through technological diversity.
Range Extender with Jet-Ignition Technology
A focus is the new range extender system for battery-electric vehicles. It is aimed at users who want to cover longer distances without charging breaks. The system will be shown for the first time at the IAA mobility and consists of a particularly efficient 800-volt high-voltage generator, driven by a compact and turbocharged combustion engine with jet-ignition technology. Thanks to the high efficiency of over 42 percent in range extender operation, direct rotor cooling to reduce the need for rare earths, and a well-thought-out packaging, the system achieves a power density of over 50
kW per liter.
The range extender concept enables the reduction of battery size ("Rightsizing") without sacrificing range – up to 1,350 kilometers according to WLTP are achievable. Mahle combines proven technologies such as turbocharging and Miller timings with modern thermal management and low-emission operating strategies.
Thermal Management Module with Integrated Heat Pump
Another highlight is the newly developed thermal management module with integrated heat pump, which Mahle presents as a world premiere. As a central unit for the entire cooling and refrigerant circuit, it controls the temperature of all vehicle components, including the passenger compartment.
The energy demand for heating in winter is a classic weakness of many electric vehicles. Compared to purely electrical heating systems, the range can be increased by up to 20 percent with the new Mahle solution.
The compact module combines climate compressor, heat exchanger, pumps, sensors, and valves in a single component. It is compatible with the currently common refrigerant R1234yf as well as with the future propane (R290) – an important future-proofing for vehicle manufacturers. Mahle also reduces the number of required coolant pumps from four to three with the new system.
Bionic Radial Fan – Quiet, Efficient, AI-Developed
As a European premiere, Mahle presents a novel bionic radial fan for vehicle air conditioning systems. The shape of the fan blades is inspired by a penguin's fin and was optimized using generative AI. According to Mahle, the result: A noise reduction of 4 dB (60 percent) and an efficiency increase of about 15 percent. The component is
suitable for passenger cars as well as for light and heavy commercial vehicles. Mahle used its internal AI tool to generate over 30 million design variants in the shortest time – an example of the strategic use of AI in the product development process.
Ethanol-Compatible Engine Components for Sustainable Existing Fleets
In the field of sustainable combustion engines, Mahle also shows an innovation. With the new powercell unit – consisting of pistons, pins, rings, and valves – the special requirements of operation with ethanol (E100) are addressed. The optimized assembly reduces fuel consumption by up to 1.5 percent and reduces CO₂ emissions by up to 70 percent over the lifecycle. It also features high wear and corrosion resistance and low lubricant consumption.
Transformation with an Efficiency Focus
In addition to product innovations, Mahle is also driving the transformation within the company with high pressure. With the new corporate structure, the group-wide efficiency program “Back on Track 2025”, and the increased use of AI in production and development, the supplier aims to strengthen its competitiveness and crisis resilience. Mahle managed to successfully implement a global restructuring in just 200 days while focusing more on local customer requirements.
Conclusion
Mahle presents itself at the IAA Mobility 2025 as an internationally positioned system partner for sustainable mobility. With concrete, near-series solutions for range extension, efficiency enhancement, and fuel substitution, the company underscores its technology-open approach. The clear appeal to politics and industry: Only through diversity, innovation, and openness can climate goals and economic stability be united.
