German firm's extender system boosts EV range to as much as 840 miles

German automotive supplier MAHLE, based in Stuttgart, has developed a new range extender system designed to significantly boost the driving range of battery-electric vehicles (BEVs) up to approximately 840 miles (1,350 km) on a single battery charge. The system features a highly efficient high-voltage generator powered by a small combustion engine, which nearly doubles the range of current longest-range BEVs. This innovation aims to address range anxiety by enabling smaller, more cost-effective batteries that reduce vehicle weight and charging times, while maintaining reliability and efficiency. MAHLE emphasizes that the system is ready for series production and integrates seamlessly into a holistic vehicle architecture. In addition to the range extender, MAHLE has introduced a compact thermal management module with an integrated heat pump that can increase EV range by up to 20% in low-temperature conditions by efficiently managing the vehicle’s cooling and heating needs without requiring additional heating systems. This module ensures optimal temperature control for the drive and energy storage systems, enhancing overall vehicle