rewrite this title New Engine Unveiled That Increases Electric Vehicle Range to 1,350 km

Mahle is offering a 1,350 km range in electric vehicles with its small range-extender engine featuring Jet Ignition technology. The system promises efficient, flexible, and biofuel-compatible hybrid solutions.

German automotive parts manufacturer Mahle introduced a new range-extender engine system at the IAA Mobility Munich 2025 fair that can significantly increase the range of electric vehicles. The company announced that its small and highly efficient motor-generator could provide a range of 1,350 km in hybrid driving. This is nearly double the range of the longest-range electric vehicles on the road today.

Mahle CEO Arnd Franz stated that they do not see their range-extender systems merely as an add-on but have designed them as a holistic driving architecture that reduces range anxiety, where smaller batteries can replace larger ones. This will lead to savings in cost, weight, and materials, and result in a new generation of affordable, efficient, and zero-emission vehicles.

Big on Impact, Small in Size

In Mahle’s new system, the 800-volt generator can operate without rare-earth magnets thanks to a special cooling system, and can continuously charge the battery by producing 85 kW of power with an efficiency of over 97%. On the engine side, the small, turbocharged engine achieves 42% efficiency with Mahle’s Jet Ignition technology. This figure is significantly higher than the average of 30% for conventional internal combustion engines. Jet Ignition uses a small pre-chamber instead of a conventional spark plug, and this chamber ensures stable combustion through rapid heat jets. As a result, fuel consumption is reduced, and the compression ratio can be increased.

According to Mahle’s calculations, it is possible to achieve a range of 1,350 km (WLTP) per charge or refill with this hybrid system. This range doubles, or even triples, the average range of electric vehicles currently on the road. Consequently, the developed range-extender system significantly reduces range anxiety on long journeys.

Additionally, the system is designed to run on renewable biofuels, allowing automakers to adapt more flexibly to their emission reduction strategies. Mahle aims to offer a ready solution in this market, which it predicts will grow by 15% annually until 2030. The company also announced that the system is ready for mass production. This development runs parallel to the review process of Europe’s 2035 combustion engine ban. Range-extender systems could emerge as a ready and viable solution to mitigate the effects of the ban.

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