ZF Develops Advanced Range Extender Technology to Address Electric Vehicle Range Anxiety

ZF Develops Advanced Range Extender Technology to Address Electric Vehicle Range Anxiety

(IN BRIEF) ZF is set to advance its range extender technology with a new generation of systems, which will go into volume production in 2026. Range extenders offer a solution to “range anxiety” in electric vehicles by using a combustion engine to generate power for the vehicle’s battery when needed. The technology increases electric driving range, reduces fuel consumption, and lowers CO2 emissions. The new systems, the electric Range Extender (eRE) and the electric Range Extender plus (eRE+), are highly integrated designs that are flexible in terms of performance, architecture, and voltage. ZF’s range extender solutions are particularly advantageous for manufacturers, offering lower costs, shorter development cycles, and simplified supply chains. The technology is gaining traction in global markets, including China, the USA, and Europe.

(PRESS RELEASE) FRIEDRICHSHAFEN, 29-Apr-2025 — /EuropaWire/ — ZF, a global leader in automotive technology, is taking another step toward revolutionizing electric vehicle (EV) mobility with the development of its next-generation electric range extender (eRE) systems. Set for volume production starting in 2026, ZF’s new range extenders will address one of the most significant barriers for electric vehicle adoption: range anxiety.

The new range extender technology – available in two versions, the electric Range Extender (eRE) and the electric Range Extender plus (eRE+) – utilizes a combustion generator coupled to an electric motor to generate energy for the vehicle’s battery. The systems are designed to extend the electric driving range, ensuring that drivers can go further without needing to worry about finding a charging station. Additionally, unlike conventional plug-in hybrids, ZF’s range extenders operate in the ideal performance range for fuel consumption, ensuring lower CO2 emissions and minimal fuel usage.

Despite the overall rise in EV adoption, range anxiety remains a key concern for many consumers, especially in regions where charging infrastructure is underdeveloped. “Although the all-electric range of passenger cars is around 500 km on average, range anxiety continues to influence the buying decisions of many potential electric vehicle customers,” said Dr. Otmar Scharrer, Senior Vice President of R&D, Electrified Powertrain Technology at ZF. “Our new range extender systems represent a true alternative to larger, more expensive batteries or plug-in hybrids, offering a practical and cost-effective solution.”

ZF’s range extenders can be easily integrated into various battery-electric vehicle (BEV) platforms, which is a major advantage for manufacturers seeking a flexible solution. The eRE and eRE+ variants are designed for high integration and can be adapted to different vehicle types, with output ranges between 70-150 kW. This modular approach allows for scalability, catering to the performance needs of a wide range of vehicles, from compact city cars to larger family models.

ZF’s advanced range extender technology is not just beneficial for customers but also for manufacturers. Compared to parallel-hybrid systems, range extenders are cost-effective and offer shorter development cycles, making them easier to implement and integrate into existing vehicle platforms. This efficiency allows automakers to reduce the complexity of production and streamline supply chain management. With China leading the charge on Range Extended Electric Vehicles (REEV), ZF’s development centers in China are playing a crucial role in the evolution of this technology.

“ZF’s range extenders offer a unique opportunity for automakers to enter the EV market while maintaining flexibility in terms of vehicle performance, battery size, and cost,” said Dr. Scharrer. “The technology is particularly attractive for manufacturers new to the market or those who want to offer an electric vehicle without compromising on range.”

ZF’s commitment to sustainability is reflected in the core principles behind its range extenders, which help manufacturers meet global emissions standards. By reducing the size of the required battery, ZF’s solutions allow for more economical electric vehicles while contributing to fleet-wide reductions in CO2 emissions. This combination of longer range, lower emissions, and lower overall costs makes range extenders an ideal solution for the evolving automotive landscape.

The anticipated production of ZF’s electric range extenders in 2026 marks another major milestone in the automotive industry’s shift toward more sustainable and flexible electric vehicle solutions. With continued global interest in the technology, ZF is positioned to remain at the forefront of this transition.

Media Contacts:

Karin Markenstein
Head of Corporate & Marketing Communications, Electrified Powertrain Technology
+49 681 920-2563
karin.markenstein@zf.com

Johannes Jerg
Electric Mobility, Artificial Intelligence
+49 7541 77-963 246
johannes.jerg@zf.com

SOURCE: ZF