MAHLE Showcases Range Extender System and Rare-Earth-Free Electric Motor at IAA TRANSPORTATION 2026

Engineered as a compact unit, the new range extender system combines a high-voltage generator, internal combustion engine, thermal and fluid management, fuel and AdBlue tanks, and exhaust gas aftertreatment into a single module. According to MAHLE, it can be integrated into existing battery-electric truck platforms, replacing roughly one-third of the battery capacity. This is expected to reduce overall vehicle weight by approximately 600 kilograms (around 1,320 lbs). 

At the heart of the system is a high-voltage generator featuring a continuous output of 110 kW and a peak output of up to 130 kW. According to MAHLE, combining the battery and range extender yields a driving range of over 800 kilometers (more than 500 miles)—with roughly 400 kilometers provided by the battery and another 400 kilometers by the range extender. In range extender mode, CO₂ emissions drop by more than 80 percent compared to conventional drivetrains. When operating on HVO100 renewable diesel, near-CO₂-neutral driving becomes possible. 

MCT Electric Motor Eliminates Rare Earths

As another world premiere, MAHLE is introducing its MAHLE Contactless Transmitter (MCT) electric motor for heavy-duty commercial vehicle electric axles. The motor functions without permanent magnets, eliminating the need for rare earth elements entirely. According to the company, the design saves up to three kilograms of rare earth magnets per vehicle, significantly lowering the drivetrain's environmental footprint. 

According to MAHLE, the MCT electric motor is about 10 percent lighter than comparable permanent-magnet synchronous motors. It delivers a peak output of 370 kW and over 900 Nm of torque, achieving an efficiency rating of 95 percent in the VECTO cycle. 

(c) MAHLE

Additional Components for Electrified Drivetrains

In addition, MAHLE is debuting an advanced Power Cell Unit (PCU) for internal combustion engines along with a new oil management system. Both components are designed to cut fuel consumption, weight, and material usage, ultimately reducing total cost of ownership (TCO). The company reports that the new oil management system can cut material costs by up to 20 percent, reduce weight by up to 25 percent, and lower the product's carbon footprint by up to 50 percent. 

A Technology-Neutral Approach to Decarbonization 

Alongside battery-electric drives, MAHLE continues to pursue a technology-neutral approach. Beyond electrification, the company views renewable fuels such as HVO100 and bio-LNG, as well as hydrogen technologies, as essential building blocks for decarbonizing road freight transport. Consequently, at IAA TRANSPORTATION 2026, MAHLE will showcase solutions for internal combustion engines capable of running on renewable fuels or hydrogen, right alongside its product lineup for battery-electric and hybrid commercial vehicles.