Global automotive supplier MAHLE has doubled down on its call for a technology-neutral approach to CO₂ emissions reduction, as it unveiled a suite of innovative propulsion and thermal technologies during MAHLE Tech Day in Stuttgart and ahead of IAA Mobility 2025. The company strongly advocated for revised European carbon dioxide legislation that includes sustainable internal combustion engines (ICEs) and renewable fuels alongside battery-electric vehicles (BEVs), hybrids, and range extenders.
Arnd Franz, CEO of MAHLE, stressed that Europe must act swiftly to include low-emission ICEs and renewable fuels in its climate strategy, warning that in the absence of legislative change, the company may halt investments in sustainable ICE technology within the continent. “We need technology neutrality in legislation so that climate protection can progress rapidly, jobs can be preserved, and European industry can regain its strength,” Franz said.
Strategic Push for Electrification and Efficiency
As part of its “MAHLE 2030+” strategy, the company is developing solutions across a wide propulsion spectrum, including electric, hybrid, range extender, and sustainable ICE powertrains. At IAA Mobility in Munich (September 9–14, 2025), MAHLE is showcasing its latest innovations under the banner “Efficiency³”.
These include:
- Range Extender for EVs: A compact, high-efficiency 85 kW range extender that alleviates range anxiety and enables battery “rightsizing.” It features an 800V permanent magnet generator, direct rotor cooling, and MAHLE’s jet ignition combustion system, achieving over 42% efficiency with low NVH and reduced use of rare earth elements. Depending on the battery size, driving ranges of up to 1,350 km are achievable.
- Thermal Management Module: A world-first integration of an air-conditioning compressor, heat exchanger, and high-efficiency heat pump into a compact module that boosts EV range by up to 20% by optimising cabin heating, especially under cold conditions. It is future-ready for refrigerant R290 (propane), ensuring sustainability and platform adaptability.
- Bionic Radial Blower: Inspired by the flippers of penguins, this air-conditioning blower is 60% quieter and 15% more efficient than conventional systems. Developed using MAHLE’s proprietary AI platform, it reflects the company’s commitment to “superhuman engineering” and bio-inspired design.
- Sustainable ICE Components: MAHLE’s new ethanol-compatible engine parts, including power cell units and valve sets, enable CO₂ reductions of up to 70% using E100 fuel. These components enhance resistance to wear, corrosion, and thermal stress while lowering oil consumption and enabling 1.5% fuel savings.
Efficiency Across Products and Processes
Amid a volatile global market, MAHLE is enhancing operational resilience through its “Back on Track 2025” programme. Recent restructuring, completed in just 200 days, has empowered regional teams, repositioned global purchasing, and improved cost efficiency.
MAHLE is also aggressively deploying artificial intelligence to optimise both production and product development. In one example, its AI-led bionic blower development involved simulating over 30 million design variants in record time.
Legislative Change Is Crucial
Franz reiterated that Europe’s climate agenda remains incomplete without a clear role for renewable fuels and sustainable ICEs. Biofuels, hydrogen, and synthetic alternatives, he argued, are critical to decarbonising the vast global vehicle fleet still dependent on combustion technology.
“If internal combustion engines powered by climate-neutral fuels are not recognised as part of the solution, we may be forced to freeze further investments in Europe,” Franz warned.
Looking Ahead
With its deep focus on thermal management, hybridisation, smart components, and alternative fuels, MAHLE is positioning itself as a solutions provider for a decarbonised mobility future—regardless of drivetrain. At IAA Mobility, the company is set to showcase how it blends mechanical engineering legacy with digital and biological innovation to create efficient, future-ready systems for all vehicle types.
“Efficiency is more than output—it’s how intelligently we get there,” concluded Dr Marco Warth, MAHLE’s Vice President for Corporate Research and Advanced Engineering.
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