As some of the global markets are showing weakness in the adoption of electric vehicles, MAHLE Group is pushing multiple forms of electrification for decarbonisation rather than completely relying on BEVs. The German auto component major believes that it is necessary to offer different types of electric vehicles, such as range extenders or hybrid vehicles, in addition to BEVs.
MAHLE manufactures a broad range of products, including electric motors, power electronics, control units and engine components and thermal management products. The company is looking at India as one of the biggest focus markets for future growth and as a global manufacturing hub. With India’s vehicle charging infrastructure development yet to keep up the pace, the company sees big opportunities for range extenders.
“For rapid and effective reduction of greenhouse gases, we consider it necessary to offer other forms of electrification beyond purely battery electric vehicles. We are also focusing on hybrid vehicles and advanced range extenders that increase the range of electric vehicles and make it easier for customers to switch from pure combustion engine vehicles,” MAHLE Group Chairman and CEO Arnd Franz said on Wednesday.
A range extender in a vehicle is a small engine or generator used to recharge the battery or provide additional power when the battery runs low. Vehicles equipped with this technology run primarily on battery power and the small ICE or generator that kicks in only to recharge the battery when it gets low, not to directly power the wheels. However, in some architecture, vehicles with a range extender are designed in such a way that wheels can be driven by the motor as well as the engine.
Amid a global landscape marked by worsening geopolitical situations, tariff hurdles and supply chain challenges, MAHLE’s management noted that the transition to electric mobility is progressing more slowly than initially anticipated. “Electric mobility is ramping up more slowly than we all hoped. The political framework conditions remain hard to plan,” Franz said.
The company’s electric mobility forecasts from two years ago have been met only by China. Franz noted that Europe and North America are lagging behind, citing the total cost of ownership as a major headwind in Europe and a clear change in policy in North America. In stark contrast, China’s growth is fueled by state subsidies for both materials and production, which resulted in overcapacity and affordable BEVs.
This divergence highlights a global market where different regions are driven by unique economic and political factors. MAHLE expects China’s share of electric vehicles with range extenders in worldwide production of electrified passenger cars and light commercial vehicles will grow by 15% per year up to 2030.
As pure battery electric vehicle sales growth has slowed in some of the key markets, companies are exploring the potential for range extenders as a way to convert traditional gasoline car drivers who are hesitant to go fully electric. In places with limited electric vehicle charging infrastructure, range extenders offer a practical middle ground, giving electric driving benefits without full dependence on charging stations. A number of major carmakers are actively exploring or developing vehicles with range extenders.
MAHLE is set to showcase its new range extender featuring its jet ignition combustion technology, direct injection, turbocharging and Miller valve timing at the Munich Auto Show in September.
When asked about India’s potential for range extenders, Fraz said: “India is certainly one of the most interesting markets for electric mobility. We work with multiple customers. We are having major programs…We believe the range extender will be accepted in India. The charge infrastructure remains a challenge in India, especially in rural areas. A 1,000-kilometre range electrically has its charm. And that’s why we believe for the market as such, the range extender means high opportunities.”
PHEVs could also play a crucial role in India’s urban mobility landscape, offering the convenience of electric cars with the added security of an ICE. However, the lack of targeted incentives and high upfront costs continues to prevent these vehicles from entering the mainstream Indian market. Compared to other hybrid vehicles, PHEVs have a larger battery that can be recharged using an external power source, allowing them to run longer on battery power alone.
The main difference between a vehicle with a range extender and a PHEV lies in how their ICE is used. While both vehicles have a battery that can be charged externally, their drivetrains are fundamentally different. In a vehicle with range extenders, only the electric motor drives the wheels in most cases, while in a PHEV, both the motor and the ICE can drive the wheels.
Apart from range extenders, hybrids and hydrogen, MAHLE is also advocating for the use of bio-fuels for decarbonization. “Any plan for rapid and effective climate protection in road traffic is incomplete without renewable fuels. In addition to hydrogen, especially in the transport sector, biofuels can make an effective contribution to individual mobility,” he added.
MAHLE urged European regulators to rethink upcoming CO₂ legislation by adopting a more inclusive approach—one that recognizes the role of sustainable internal combustion engines and alternative fuels. Franz argues that embracing “technology diversity” is essential not just for meeting climate targets, but also for bolstering Europe’s automotive sector and protecting jobs across the region.