Mahle adds a thermal engine to electric trucks to achieve over 800 km of range

Mahle is accelerating its development of range extenders for electric trucks. The supplier is now working with several industrial vehicle manufacturers on initial prototypes. Its system promises a range of over 800 kilometers.

To electrify long-distance road transport, continuously increasing battery size isn’t the only solution. Mahle advocates for an intermediate approach that maintains electric propulsion while incorporating a small internal combustion engine to generate electricity when the battery starts running low on power.

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800 km of range with a smaller battery

Introduced in the summer of 2026, Mahle’s range extender is now entering a new phase. At the IAA Transportation in Hanover, the supplier announced that it has launched several projects with automakers. Prototypes are currently in development and are set to undergo real-world testing.

Mahle has not yet revealed the names of its partners or a timeline for potential mass production. However, the technical principle is already known, as it is also used in automobiles. An 110 kW high-voltage generator, capable of reaching 130 kW at peak times, is paired with a thermal engine. The system includes thermal management, fuel and AdBlue tanks, as well as an emission control system.

This installation replaces part of the battery. According to Mahle, this allows one-third of its capacity to be eliminated. Despite the addition of a thermal engine, the truck’s total weight decreases by 600 kg. The manufacturer claims around 400 km of range from the battery, with an additional 400 km provided by the extender, resulting in a total of over 800 km.

A solution to the lack of charging stations for heavy trucks

The advantage of this architecture is primarily reducing reliance on fast-charging infrastructure. However, this solution still depends on fuel and generates emissions when the extender is in use. Tests will therefore need to determine whether this compromise is truly worthwhile in terms of cost, consumption, and emission reduction compared to an electric truck with a larger battery.

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Mahle also takes advantage of the IAA Transportation show in Hanover to unveil an electric motor with 370 kW of power that lacks permanent magnets and thus rare earth elements.