IAA 2026: MAHLE aims to reconcile the electric truck with the reality of transport

What if the real accelerator for the electric truck was ultimately… not a bigger battery? Just a few weeks ahead of the IAA Transportation in Hanover, MAHLE is unveiling an innovation that could well reshuffle the deck. Its new range extender promises to eliminate one of the main concerns for transport operators: the fear of running out of range before finding an available charging station.

On paper, the solution seems almost obvious. In reality, it could allow the electric heavy truck to take a decisive step forward.

For several years, manufacturers have been competing with announcements surrounding electric heavy trucks. Vehicles are progressing rapidly, but in the field, the same questions keep coming up: where to recharge? How long will we have to wait? What should we do when a charging station is occupied or out of service?

This is precisely where MAHLE intends to step in.

Its new system works like a genuine range insurance policy. As long as the battery is sufficient, the truck runs exclusively on electricity. When it reaches a critical level, a compact internal combustion engine drives a high-voltage generator capable of directly supplying the electric drivetrain.

The objective is not to turn the truck into a conventional hybrid. The internal combustion engine does not drive the wheels; it simply produces the energy needed to continue the journey when circumstances require it.

A philosophy that could reassure many operators who are still hesitant to make the switch to electric.

With this architecture, MAHLE announces a total range exceeding 800 kilometres. In practice, around 400 kilometres are provided by the battery, while the range extender provides the additional kilometres.

Enough to cover practically all daily operations without imposing total dependence on a charging network that remains, even today, largely insufficient for heavy-duty transport. “Our range extender is an intelligent backup unit that intervenes only when necessary,” explains Marco Warth, Head of Advanced Research at MAHLE.

The other advantage of this technology is less spectacular, but probably more important economically. Since the range extender takes over when the battery is almost empty, the battery can be significantly smaller.

MAHLE estimates that its system replaces around one third of the battery capacity normally installed. The result: the truck gains nearly 600 kg, including around 400 kg on the rear axle.

Fewer batteries also mean a lower purchase cost and more available payload, two arguments that will immediately appeal to transport operators.

The manufacturer has designed its system as a completely self-contained module. Inside are the internal combustion engine, generator, cooling systems, fluid management, exhaust gas treatment, as well as the fuel and AdBlue tanks.

The entire unit simply takes the place of part of the batteries, making it easier to integrate into existing electric truck platforms. An approach that could accelerate its adoption by manufacturers.

MAHLE will also use the IAA to present another world first: an electric motor for heavy trucks that contains no permanent magnets.

Thanks to its MCT (MAHLE Contactless Transmitter) technology, it completely eliminates the need for rare earths, whose supply is today a major strategic issue.

With 370 kW, more than 900 Nm of torque and a claimed efficiency of close to 95%, this motor aims to be lighter, more efficient and more sustainable.

Beyond the innovations, MAHLE is delivering a message that is likely to spark debate. According to its CEO Arnd Franz, relying solely on fully electric technology would be a mistake.

In his view, the transition will necessarily involve several complementary technologies: batteries, renewable fuels, hydrogen, internal combustion engines compatible with biofuels… and now range extenders.

A position that ultimately echoes that of many transport operators, who face the realities of the field every day, long before the targets set in the offices of Brussels.

Because ultimately, the problem is not so much the electric truck as what surrounds it. Vehicles are progressing rapidly. Batteries are too. However, the deployment of charging infrastructure is still struggling to keep pace. As long as this situation persists, many transport operators will continue to hesitate before investing.

With its range extender, MAHLE is not claiming to replace charging stations. The German equipment manufacturer is simply offering a pragmatic solution that allows operators to continue working without being constrained by the current limitations of the network.

At a time when Europe is pushing fleets towards decarbonisation, this approach could well prove to be one of the most concrete innovations of this 2026 edition of IAA Transportation.

Text: Fabien Calvet Photos: MAHLE