MAHLE introduces range extender, ethanol solutions, and smart charging innovations at IAA Mobility 2025

MAHLE’s wireless charging with user-friendly positioning system
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(IN BRIEF) MAHLE is presenting a diverse portfolio of production-ready technologies at IAA Mobility 2025 in Munich, highlighting electrification systems, ethanol-compatible engine components, and smart charging innovations under its strategic framework “Efficiency³.” Key highlights include a range extender system delivering up to 1,350 km of driving range, a thermal management module that improves efficiency and range by 20% in cold weather, and ethanol engine technology capable of cutting CO₂ emissions by up to 70%. MAHLE is also showcasing a bio-inspired radial blower developed using AI, expanded charging solutions including inductive and mobile systems, and advanced service tools for diagnostics and battery testing. CEO Arnd Franz emphasised that Europe’s competitiveness, climate protection, and employment depend on embracing all technologies rather than focusing on a single pathway.

(PRESS RELEASE) STUTTGART, 8-Sep-2025. — /EuropaWire/ — MAHLE is using IAA Mobility in Munich to showcase a broad portfolio of solutions designed to cut CO₂ emissions and strengthen Europe’s competitiveness through technological diversity. The globally active group is introducing new systems for electrification, advanced thermal management, biofuel-ready combustion engines, and smart charging infrastructure – all developed with a clear focus on immediate applicability.

“Our products are not visions for the distant future – they are ready for series production and directly address our customers’ real challenges,” said Arnd Franz, Chairman of the Management Board and CEO of MAHLE. “Europe must embrace a wide range of technologies if it is to deliver climate protection, safeguard employment, and maintain industrial strength.”

Electrification breakthroughs to ease range concerns
MAHLE’s new range extender system demonstrates how electric vehicles can achieve up to 1,350 km of driving range (WLTP), thanks to its highly efficient 85 kW generator operating on an 800-volt system. Its compact design reduces space and material requirements while allowing carmakers to right-size batteries, lower costs, and shorten charging times.

IAA world premiere: The range extender system from MAHLE consists of a highly efficient high-voltage generator driven by a small internal combustion engine.

Complementing this is a new thermal management module with integrated heat pump, which can increase range by up to 20% in low temperatures. With its modular compact design and fewer required components, the system optimises both energy use and OEM development costs.

Harnessing biofuels for immediate decarbonisation
Recognising the continuing importance of internal combustion engines, MAHLE is presenting ethanol-compatible engine components capable of operating on 100% ethanol. Specially developed pistons, valve sets, and piston rings make the technology highly durable and efficient. When powered by sustainably produced E100, the system can reduce CO₂ emissions by up to 70%, with near carbon-neutral operation possible – and crucially, it can be applied to the existing vehicle fleet without compromising performance.

Efficiency inspired by nature and powered by AI
Innovation at MAHLE extends beyond engines and batteries. Its new bionic radial blower, inspired by the hydrodynamics of penguin flippers and developed using AI-driven “superhuman engineering,” is 60% quieter and 15% more energy-efficient than conventional designs.

Smarter charging solutions and real-world testing
The company’s charging division, chargeBIG, is expanding with the world’s smallest wallbox and a mobile unit for construction sites and events. MAHLE’s inductive charging technology, recognised by SAE International as a global standard, achieves efficiencies above 92% in everyday use. At IAA, MAHLE is also demonstrating its AI-based cabin comfort system, advanced air purification, and the E-HEALTH Charge diagnostic tool, which can evaluate battery performance in just 15 minutes.

Visitors can also explore the MAHLE Workshop Heroes Van, currently touring European repair shops with service equipment for vehicle diagnostics, calibration, and battery testing.

With its “Efficiency in Motion” mission and “Efficiency³” strategy – electrification, thermal management, and sustainable combustion – MAHLE underscores that climate neutrality will only be achieved through a mix of technologies, not one solution alone.

About MAHLE
MAHLE is a leading international development partner and supplier to the automotive industry with customers in both passenger car and commercial vehicle sectors. Founded in 1920, the technology group is working on the climate-neutral mobility of tomorrow, with a focus on the strategic areas of electrification and thermal management as well as further technologies to reduce carbon emissions, such as fuel cells or highly efficient, clean combustion engines that also run on renewable fuels, such as hydrogen. Today, one in every two vehicles globally is equipped with MAHLE components.

MAHLE generated sales of €11.7 billion in 2024. Employing just under 68,000 people at 135 production locations and 11 technology centers, the company is represented in 28 countries. (as at: 12/31/2024)

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Media Contacts:

Manuela Höhne
Director Corporate Communications & Marketing
Phone: +49 173 3180217
E-Mail: manuela.hoehne@mahle.com

Kerstin Cynthia Lau
Head of Media Relations
Phone: +49 173 6180956
E-Mail: kerstin.cynthia.lau@mahle.com

SOURCE: MAHLE