Range Extenders

Pure EVs typically require bulky and expensive battery packs to achieve acceptable range. Extended range electric vehicles (E-REVs) offer a viable solution using an onboard generator (range extender), enabling a significant battery size reduction.

Our Value Add

  • Experienced in range extender engine development and vehicle applications
  • Range extender requirements are fully understood and optimized
  • Focus on Range extender main characteristics
    • low cost
    • small package volume
    • good NVH attributes
    • competitive fuel efficiency


Our Tools, Facilities and Services

  • Customer tailored engine design, development and full vehicle integration
  • Tailored solutions for various vehicle applications
  • Fully equipped and secure vehicle build facilities
  • Engine and vehicle control using MAHLE Flexible ECU (MFE)


Customer Benefits

  • Typical 12-month timescale from clean sheet to running engine
  • Comprehensive vehicle packaging design and installation service
  • Optimized thermal management systems
  • Class-leading NVH behaviour
  • Wide variety of operating strategies including GPS based control

MAHLE Range Extender Engine

MAHLE Range Extender Vehicle