MAHLE unveils range extender engine and rare earth free electric motor for heavy trucks
By Eve
Automotive supplier MAHLE has launched a range extender system for heavy-duty electric trucks that replaces approximately one third of battery capacity with a compact diesel engine and generator unit. The self-contained assembly delivers 110 kW continuous power (130 kW peak) and reduces total vehicle weight by around 600 kg while cutting rear axle load by 400 kg. MAHLE also introduced a Contactless Transmitter electric motor for commercial vehicle drive axles that eliminates permanent magnets, saving up to 3 kg of rare earth materials per vehicle and achieving 10% lower weight than permanent magnet synchronous motors.
Why it matters: The range extender offers fleet operators a lighter, potentially lower cost alternative to full battery electric trucks for long haul applications, while the rare earth free motor addresses supply chain risks and material cost volatility in commercial EV procurement. Both technologies target the heavy duty segment where charging infrastructure gaps and payload constraints remain barriers to electrification.