Mahle Launches Scalable Range Extender Solutions for the Transition to Electric Mobility

With the global shift to electric vehicles (EVs) progressing more slowly than expected, Mahle is expanding its portfolio with transitional technologies. One of the most in-demand offerings—especially in China—is its new family of modular, scalable range extenders, delivering outputs from 30 kW to 120 kW.

Addressing Range Concerns in the EV Market

While concerns over EV driving range are often unfounded, they remain a deciding factor for many buyers choosing between electric and combustion vehicles. In China, range extender-equipped vehicles (REEVs) are seeing renewed interest, particularly in rural areas, where they combine long-distance capability with electric driving benefits and attractive tax incentives.

The concept isn’t new—BMW offered a 25 kW range extender in its i3 in 2013. But a €5,000 price premium, added weight of 120 kg, and a restricted nine-liter fuel tank limited its appeal.

Range Extender vs. Plug-In Hybrid

The plug-in hybrid (PHEV) combines a combustion engine with one or more electric motors that can mechanically drive the wheels. A REEV, by contrast, is a pure electric vehicle with a smaller battery; its combustion engine solely powers a generator—never the wheels.

In real-world use, REEVs can struggle under sustained high-power demands. Efficiency losses and extra weight can be drawbacks, especially without incentives.

China’s Incentive-Driven Demand

In China, REEVs fall under the classification of New Energy Vehicles (NEVs), along with BEVs, PHEVs, and fuel cell models. They enjoy an exemption from the 10 % luxury tax imposed on conventional vehicles.

• 2024–2025: Full exemption up to ¥30,000 (~US$4,179)
• 2026–2027: 50% exemption up to ¥15,000 (~US$2,089)
• 2028: Scheduled end of these tax benefits

NEVs now account for about 27.7 % of new car sales in China, though conventional vehicles remain dominant in rural areas.

Mahle’s Modular Range Extender Platform

Mahle’s new range extender family, set to debut at IAA Mobility 2025, uses a 500 cc cylinder base that is modular and scalable:

• 2-cylinder – about 30 kW
• 3-cylinder – mid-range output
• 4-cylinder – up to 120 kW

The accompanying 85 kW continuous generator, powered by an 800 V permanent magnet motor with direct rotor cooling, achieves over 97 % peak efficiency and high power density—while reducing reliance on heavy rare-earth materials.

Efficiency & Emissions Compliance

The turbocharged engine incorporates Mahle Jet Ignition for cleaner combustion, along with direct injection, turbocharging, and the Miller cycle for enhanced efficiency.

It complies with both Euro 7 and China 6 emissions standards, delivering over 42 % thermal efficiency and enabling WLTP driving ranges of up to 1,350 km.

Mahle at IAA Mobility 2025

From September 9–14, 2025, Mahle will showcase its range-extender technologies, CO₂-reducing components, and electrification initiatives. Find them in Hall A1 at IAA Mobility in Munich.