German automotive parts manufacturer Mahle unveiled a revolutionary technology for electric vehicles at the IAA Mobility Munich 2025 trade fair. The company announced that its new range-extending motor-generator system can deliver a range of up to 1,350 kilometers in hybrid vehicles. This doubles the range of even the longest-range electric vehicles currently on the market.

This electric vehicle motor offers 1,350 km

Mahle CEO Arnd Franz stated that they didn’t view this system as mere additional hardware, but rather designed it as a holistic architecture that allows smaller batteries to replace larger ones. This approach reduces vehicle cost, weight, and material usage, while enabling the production of a new generation of more affordable, efficient, and zero-emission vehicles.

At the heart of the system is an 800-volt generator operating without the use of rare-earth magnets. This generator continuously generates 85 kW of power with over 97 percent efficiency, charging the battery.

On the engine front, a small, turbocharged engine stands out with Mahle’s proprietary Jet Ignition technology. This technology, which uses a small pre-chamber instead of conventional spark plugs, ensures more consistent fuel combustion. This allows the engine to achieve a remarkably high thermal efficiency of 42 percent.

This figure far exceeds the average 30 percent efficiency of standard internal combustion engines. This technology both reduces fuel consumption and allows for increased compression ratios.

According to Mahle’s calculations, this hybrid system can achieve a WLTP range of up to 1,350 kilometers on a single charge or refueling. This eliminates range anxiety for electric vehicle users on long journeys. Furthermore, the system’s design to run on renewable biofuels provides automakers with flexibility in their emissions reduction strategies.

The company announced that this system is ready for mass production. This technology, which aligns with the review process for the planned 2035 European car ban, stands out as a viable solution that could mitigate the potential impacts of the ban. Mahle estimates that this market will grow by 15 percent annually until 2030 and aims to offer a ready-made solution in this area.