German automotive supplier Mahle has introduced a groundbreaking multi-fuel engine-generator system at the IAA Mobility Munich 2025, a development poised to significantly extend the driving range of electric vehicles (EVs). This compact and highly efficient unit is designed to enable EVs to travel up to 838 miles (1,350 kilometers) on a single charge and refueling, directly addressing the issue of range anxiety. The system integrates a small, turbocharged engine with a state-of-the-art generator, offering drivers a seamless transition between electric and hybrid driving modes for enhanced flexibility.
Mahle's CEO, Arnd Franz, has been a strong advocate for range-extended EVs, identifying them as a critical component for the future of the automotive sector. He has noted that Europe lags behind China and North America in adopting this technology, attributing this to political complexities. In response to industry concerns, European Commission President Ursula von der Leyen has agreed to expedite the review of the 2035 ban on combustion-engine vehicles. Originally scheduled for 2026, this review will now occur before the end of 2025, potentially paving the way for broader acceptance of diverse automotive technologies, including hybrids and vehicles using sustainable fuels, to meet emission reduction goals.
The Mahle range-extender system is engineered to operate on renewable biofuels, aligning with the automotive industry's increasing commitment to sustainability. Projections indicate that the market for range-extended electric vehicles will grow by 15% annually through 2030. Mahle is strategically positioning itself to be a key player in this expanding market, offering consumers greater travel freedom and mitigating the limitations of current battery-electric vehicles. The company's commitment to technological diversity is further demonstrated by its development of components for internal combustion engines that can run on up to 100% ethanol, a move that could significantly cut CO2 emissions from the existing vehicle fleet.
Mahle's approach, as articulated by CEO Arnd Franz, emphasizes that Europe's competitiveness, climate protection, and employment depend on embracing a wide spectrum of technologies rather than relying on a single pathway. The company's products, including the range extender and thermal management modules, are production-ready and directly address current automotive challenges, aiming to foster greater market acceptance of electric vehicles. The global electric vehicle range extender market is projected to grow significantly, with estimates suggesting it will surpass USD 2.75 billion by 2034, driven by increasing demand for extended driving ranges and advancements in engine downsizing. North America currently leads this market, with the U.S. at the forefront, supported by government incentives for EV adoption and stricter emission standards for automakers. The European Commission's accelerated review of the 2035 combustion engine ban, driven by industry pressure and concerns about infrastructure and consumer demand, could allow for a more inclusive approach to decarbonization, potentially benefiting technologies like Mahle's range extender. This review, expected to conclude before the end of 2025, may introduce exemptions for vehicles using climate-neutral fuels and plug-in hybrids, reflecting a growing acknowledgment of technological diversity in achieving emissions targets.