MAHLE Champions Technology Diversity to Accelerate Decarbonisation
'We have a clear commitment to climate protection. And to e-mobility. We are ready,' Arnd Franz told an audience of international journalists on Wednesday. In addition to products for pure e-mobility, MAHLE is also focusing its efforts on hybrid vehicles and advanced range extenders to boost the ranges of electric vehicles and to make it easier for customers to change over from pure ICE vehicles. Especially China is currently recording strong growth in these electric drive systems. It is forecast that the share of electric vehicles with range extenders in worldwide production of electrified passenger cars and light commercial vehicles will grow by 15 percent per year up to 2030. MAHLE intends to share in this growth.
The MAHLE CEO also mentioned the high decarbonization potential of renewable fuels, which is not yet being fully tapped. 'Any plan for rapid and effective climate protection in road traffic is incomplete without renewable fuels. In addition to hydrogen, especially in the transport sector, biofuels can make an effective contribution to individual mobility,' he emphasised. He added that this would allow more rapid progress, especially with respect to the vehicle fleet. The share of renewable fuels, i.e. biofuels and synthetic fuels, used in road traffic would need to rise to 30 percent by 2030 in order to reach the climate goals. 'MAHLE technologies already allow the direct use of renewable fuels without any compromises.'
Franz said that Europe was facing a crucial decision for the future with respect to CO2 emissions regulations. 'The revision of CO2 legislation in Europe must not be delayed. Internal combustion engines operated using climate-neutral fuels must be recognised as part of the solution.' In the present regulatory situation, he said that MAHLE as a company was forced to consider a stop of all investments for the expansion and replacement of capacities for sustainable internal combustion engines in Europe. If the EU was not prepared to change its position with regard to a ban on ICE vehicles, such an investment stop would be the logical consequence.
With its MAHLE 2030+ strategy, MAHLE, as a globally active automotive supplier, covers all types of powertrains which can make a key contribution to climate protection: electrification and sustainable internal combustion engines as well as thermal management to boost the efficiency and performance of the two technologies.
Efficiency drives the transformation
In a challenging business environment where trade relations face global uncertainties, MAHLE is increasingly committed to efficiency in connection with the current transition. This also applies to its processes, with a view to enhancing its competitiveness and becoming more crisis-proof.
An example of successful efficiency measures is the new company structure that MAHLE has recently implemented throughout the world from its own resources in only 200 days. This also included the repositioning of purchasing and the strengthening of regional responsibilities with a view to reacting more effectively to customers' local requirements. The group's internal cost effectiveness and profitability program 'Back on Track 2025' continues to run at full speed. The plants are also working consistently on efficiency improvements. This approach includes initiatives to reduce energy consumption such as the shut-off management of production equipment or the installation of photovoltaic thermal systems.
MAHLE is also expanding the use of artificial intelligence (AI) within the company. The use of machine learning in selected areas optimises both direct production and indirect processes. Furthermore, generative AI is being put to successful use in product development in order to save time and resources in the development of future-oriented innovations. The most recent development example is the bionic radial blower for air conditioning systems – inspired by a penguin's flippers – which MAHLE will be showcasing at IAA Mobility.
MAHLE at IAA Mobility 2025
Under the motto of 'Efficiency3', MAHLE is presenting the latest developments in its three strategic areas at this year's IAA Mobility in Munich: a range extender to boost the range of electric vehicles, a compact thermal management module with integrated heat pump to significantly extend the range of electric vehicles and ethanol-compatible engine components which will considerably reduce both the fuel consumption and the CO2 emissions of internal combustion engines.
Dr. Marco Warth, Vice President Corporate Research and Advanced Engineering at MAHLE, said: 'At MAHLE, we not only define efficiency as the optimum relationship between effort and results – we also breathe life into this principle with innovative solutions that conserve resources, save energy and boost the transition to sustainable mobility.'
Many car drivers have a positive attitude to e-mobility. However, it has become clear that they wish to combine the benefits of an electric car with the security offered by additional range. Electric vehicles with range extenders can therefore help to further accelerate the adoption of electric vehicles by relieving consumers' range anxiety. Range extenders supply energy for the electric motor when the charge of the vehicle battery has been depleted.
The new range extender from MAHLE, which is being showcased for the first time at IAA Mobility, will increase the market acceptance of battery-electric vehicles throughout the world and allow the cost-effective, resource-efficient 'rightsizing' of batteries without customers having to accept long waits at battery charging stations on long trips.
The new system, with a rated continuous output of 85 kilowatts (kW), consists of an especially efficient high-voltage generator powered by a compact internal combustion engine. The heart of the 800 V generator is a permanently excited electric generator with a fully integrated cooling system. In addition to a high peak efficiency in excess of 97 percent, this design ensures a high continuous performance density (in excess of 50 kW per liter), minimising material and space requirements as well as costs. One of the special features of the MAHLE design is the high-performance direct cooling of the rotor, which significantly reduces the need for heavy rare earth elements, among other benefits.
The boosted high-tech internal combustion engine used in the range extender features MAHLE jet ignition combustion technology, direct injection, turbocharging and Miller valve timing, i.e. the special control of the intake valves of an internal combustion engine to allow more efficient combustion and ensure lower pollutant emissions. In range extender operation, the engine offers a high efficiency of more than 42 percent and its noise level is inconspicuous.
'It is small, lightweight, easy to integrate and conserves resources – MAHLE's range extender is a convincingly compact, efficient power pack for drive systems,' said Warth. The technology toolkit for range extender engines is also supplemented by specially developed engine components such as pistons and valves. In the WLTP (Worldwide Harmonized Light Vehicles Test Procedure), enormous ranges of up to 1,350 km can be achieved, depending on the vehicle and the battery size.
Thermal management module boosts efficiency and range
MAHLE has developed a new thermal management module that boosts the system efficiency of an electric vehicle and therefore also the range available with a battery charge. MAHLE is showcasing the product as a world premiere at IAA Mobility. As the central interface for the entire cooling and refrigerant cycle of the vehicle it ensures that each component of the drive and energy storage system is maintained at the right temperature at all times under all climate conditions at the same time as ensuring a comfortable climate in the passenger compartment.
Especially heating the passenger compartment in the winter is a challenge with electric vehicles. As an electric drive system generates significantly less heat than an internal combustion engine, very little energy from this source is available for heating. The heat required for the passenger compartment must be generated in addition to the operation of the drive system. High efficiency is essential as the energy storage facility of the vehicle is the traction battery. Energy used for heating is not available for propulsion.
To ensure maximum range per battery charge even when heating is needed in the winter, MAHLE has integrated a high-efficiency heat pump in the thermal management module. The module combines air conditioning compressor, heat exchanger, refrigerant pumps, sensors and valves in a single unit. This reduces space requirements, development work and costs. In addition, the overall system is considerably more efficient, allowing the range to be boosted by up to 20 percent compared with a system using electric heaters.
'The advantage of MAHLE in our competitive environment is our comprehensive components and systems expertise developed through our in-house development and production activities. This way, we can offer holistic solutions which are perfectly harmonised with each other,' said Marco Warth.
The module is designed for R1234yf, the refrigerant currently used but can also be operated with the alternative future refrigerant R290 (propane) with minor modifications. 'This provides automakers with security for the future when integrating the system in current vehicle platforms as extensive design modifications will not be needed to change the system over to the new refrigerant,' Warth explained. Thanks to the modular, compact system design, only three refrigerant pumps instead of four will be needed for the vehicle. The system is currently being developed, and series production will start within the next two years.
Bionic radial blower – form follows nature
At IAA Mobility, MAHLE is showcasing as a European premiere a ground-breaking radial blower for automotive air conditioning systems that boosts efficiency at the same time as significantly reducing noise levels. This product has been developed especially for vehicles with challenging installation space conditions and takes nature as its model. The aerodynamic shape of the blower blades is inspired by the flippers of a penguin, which glides nimbly and rapidly through the water.
Thanks to its innovative design, the bionic blower is four decibels (dB) or 60 percent quieter than a conventional component. At the same time, its efficiency is improved by about 15 percent as the motor requires less energy as a result of the optimised design. MAHLE is setting new standards with this innovative design. The bionic radial blower can be used in all types of passenger cars as well as light and heavy commercial vehicles.
The development process was considerably accelerated by the use of an in-house AI tool and the first prototypes were produced within a very short space of time. The engineers at MAHLE call this process, in which they guide the AI system and feed it with data and information, 'superhuman engineering'. This process created more than 30 million virtual designs in a very short space of time.
Ethanol engine – MAHLE is ready for sustainable fuels
MAHLE underscores its technology diversity in the drive system sector with components for internal combustion engines that can be operated on renewable fuels. Life cycle analyses have shown that carbon dioxide emissions can be reduced by up to 70 percent in operation on pure ethanol (E100).
With a new system consisting of pistons, piston pins and rings, called a 'power cell unit', as well as valve sets, MAHLE has taken into consideration the special requirements for ethanol operation. The optimisation of components within the overall system ensures minimum lubricating oil consumption with high resistance to wear, corrosion and thermal stress. The benefits are lower greenhouse gas emissions and the conservation of valuable resources. In addition, the power cell unit allows fuel savings of up to 1.5 percent. This convincingly demonstrates that there is still potential for improvement even after more than 100 years of engine development and that CO2 savings can be achieved.
Try Our AI Features
Explore what Daily8 AI can do for you:
Comments
No comments yet...
Related Articles
Bangkok Post
2 days ago
- Bangkok Post
EU could win trade war with US
The US-EU trade deal has been heavily criticised as a capitulation by the bloc. But if you dive into the agreement details, the European Union is likely not only to suffer less than the US but may even see its economy benefit from the new global tariff regime. The EU, on July 28, came to an agreement with the US that set base levies on EU goods at 15%, below the 30% rate US President Donald Trump had threatened, though still much higher than tariffs were before the trade war began. Many analysts and journalists alike are adamant that the trade deal the EU struck was a big win for the US and a major loss for the EU. Even French Prime Minister Francois Bayrou seems to think so. The main thrust of the argument is that the EU should have been strong enough to inflict measurable pain on the US, but instead made lots of promises without getting much in return. Plus, some European leaders are concerned that their exporters will suffer from lower US demand in the short term. Allow me to disagree and state that, as it stands today, the EU is winning the trade war. First, let us compare the EU trade deal with the agreement that one of Europe's major competitors, Japan, struck with the US just five days earlier. Both countries were hit with a baseline tariff rate of 15%, and both made much-derided promises to boost investment in the US. While Europe's total pledge is larger in nominal terms, it only represents around 7% of the EU's GDP compared to over 13% for Japan. The numbers clearly suggest the EU got a better deal than Japan, even without accounting for the fact that Japanese businesses depend more on exports to the US than their EU counterparts. Moreover, neither the EU's promised US$600 billion investments in the US nor the purchase of $750 billion in energy commodities is arguably a real concession. Over the last three years, EU businesses have invested some $605 billion in the US, so investing another $600 billion in the next three years would likely have happened regardless. And as Reuters Open Interest columnist Clyde Russell explained, it is delusional to think the US can deliver $750 billion in energy commodities to the EU in the next three years. On top of this, modelled projections of the impact of the tariffs on the US and other countries suggest that, based on the announced tariff levels, the US will suffer more than the EU both in terms of GDP and inflation. Over the next 12 months, my model -- which is a global trade model that considers the dynamic relationships between trade, growth, inflation, and foreign exchange rates -- forecasts a 1 percentage point (pp) increase in US inflation and a 0.4 pp decline in GDP growth. The Yale Budget model anticipates a similar hit to GDP, but it anticipates a larger 1.8 pp boost to inflation. Meanwhile, my model indicates that in the next 12 months, the impact on EU inflation and growth should both be in the order of 0.2 pp to 0.3 pp. In short, the EU appears set to suffer less from the new tariff regime than the US in the next year. And in the medium term, the EU could very well be a net winner from this new trade environment, as new supply chains are established in response to the higher global tariff environment. In fact, my model indicates that, based on the tariffs currently announced, the EU's GDP could actually increase by around 0.1 pp compared to a no-tariff scenario. Why? Because China and several other economies like India, Brazil and possibly Switzerland face much higher tariffs than the EU, which could allow EU exporters to gain market share from these international competitors. After all, US businesses and consumers who cannot replace imported goods with domestically produced ones will seek to find the cheapest possible imported good. And while Chinese imports tend to be cheaper than those from Europe, they will now come with much higher tariffs, eroding China's price advantage. Some recent economic data releases suggest these model forecasts could be onto something. Consider new manufacturing orders in recent PMI surveys. In the US, they crashed in April after rising in the first quarter due to businesses front-running tariffs, and they continue to hover well below the crucial 50-point mark denoting expansion and contraction. Meanwhile, in the EU, this indicator has accelerated and remains well above the levels seen in the US. Where does that leave us? Sentiment in the EU following the trade deal appears to have become too negative, while investors simultaneously appear too complacent about America's economic prospects. This sounds like where we were at the beginning of the year, right before Europe started outperforming. Reuters
Bangkok Post
7 days ago
- Bangkok Post
The scramble for the world's critical minerals
The world's superpowers have developed a seemingly insatiable appetite for the critical minerals that are essential to the ongoing energy and digital transitions, including rare-earth metals (for semiconductors), cobalt (for batteries), and uranium (for nuclear reactors). The International Energy Agency forecasts that demand for these minerals will more than quadruple by 2040 for use in clean-energy technologies alone. But, in their race to control these vital resources, China, Europe, and the United States risk causing serious harm to the countries that possess them. As it stands, China is leading the pack, having gained ownership or control over an estimated 60-80% of the critical minerals that are needed for industry (such as for magnets) and the green transition. This control extends across the supply chain: China is heavily invested in mining across Africa, Central Asia, and Latin America, and has been building up its processing capabilities. For Western powers, China's quasi-monopoly over critical minerals looks like an economic and national-security threat. This fear is not unfounded. In December 2024, China restricted exports of critical minerals to the US in retaliation for US restrictions on exports of advanced microchips to China. Since then, US President Donald Trump has forced Ukraine to relinquish a significant share of its critical minerals to the US in what he presents as repayment for American support in its fight against Russia. Mr Trump also wants US sovereignty over mineral-rich Greenland, to the dismay of Denmark. And he has suggested that Canada, with all its natural resources, become America's 51st state. The European Union, for its part, has sought its own mining contracts, such as in the Democratic Republic of the Congo (DRC), touted as the "Saudi Arabia of critical minerals". From the Scramble for Africa in the 19th century to Western attempts to claim Middle Eastern oil in the 20th century, such resource grabs are hardly new. They reflect a fundamental asymmetry: less industrialised developing economies tend to consume fewer resources than they produce, whereas the opposite is true for developed economies -- and, nowadays, China. In principle, this asymmetry creates ideal conditions for mutually beneficial agreements: industrialised economies get the resources they desire, and non-industrialised economies get a windfall, which they can use to bolster their own development. But, in reality, vast natural-resource endowments have proven to be more of a curse than a blessing, with resource-rich countries often developing more slowly than their resource-poor counterparts. A key reason for this is that developed economies have more economic clout, advanced technology, and military might -- all of which they bring to bear to acquire the resources they seek. For example, European imperial powers used steam-engine technology to help them explore and exploit Africa for resources like copper, tin, rubber, timber, diamonds, and gold in the 19th century. This, together with more advanced weaponry and other technologies, meant that, far from offering local communities fair compensation for their valuable resources, European powers could subjugate those communities and use their labour to extract and transport what they wanted. But even countries that are exporting their resources for a profit have often struggled to make progress on development, not only because of imbalanced deals with more powerful resource importers, but also because their governments have often mismanaged the associated bonanzas. It does not help that resource-rich countries and regions often grapple with internal and external conflicts. Consider the mineral-rich provinces of the DRC, such as Katanga and North Kivu, which have long suffered from violence and lawlessness, fuelled by neighbours such as Rwanda and Uganda. Today, the advance of the Rwanda-backed M23 rebels is fuelling bloodshed in eastern Congo -- and creating an opportunity for outside powers to gain access to critical minerals. The DRC-Rwanda peace agreement brokered by the Trump administration promises precisely such access to the US, in exchange for security guarantees. But the resource curse is not inescapable, especially for countries with strong outward-facing institutions to manage the economy's external relations, including its resource sector's ability to attract investment and generate revenues for the state, and inward-facing institutions to govern how those revenues are used. If a country is to translate its resource endowments into economic development and improvements in human well-being, both have a critical role to play. Outward-facing institutions must negotiate fair and transparent mining contracts with multinational corporations and strengthen local governments' ability to do the same. Such contracts should include local-content requirements, which keep more high-value-added processing activities at home, increase local employment, and strengthen the capacity of local suppliers and contractors. Since acquiring a 15% stake in De Beers, Botswana has sought to ensure that diamond cutting -- not just mining -- occurs domestically, which requires inward-facing institutions to deliver adequate investment in these capabilities. Inward-facing institutions must also manage risks raised by resource extraction, from health and environmental damage (deforestation, biodiversity loss, pollution) to labour-rights violations (including child labour). Unfortunately, as it stands, many mineral-rich countries are falling far short, leading some to advocate boycotts of critical minerals coming from conflict zones or countries using forced labour. While such boycotts are unlikely to sway these governments, they could convince multinationals and foreign governments to demand better enforcement of environmental and social standards from countries with which they do business. Ultimately, however, it is up to mineral-rich countries to defend their interests and make the most of their endowments. This starts with efforts to strengthen institutions. ©2025 Project Syndicate Rabah Arezki, a former vice president at the African Development Bank, is Director of Research at the French National Centre for Scientific Research and a senior fellow at Harvard Kennedy School. Rick van der Ploeg is Professor of Economics at the University of Oxford and University Professor of Environmental Economics at the University of Amsterdam.
Bangkok Post
7 days ago
- Bangkok Post
Forward bookings dip amid border row
Foreign forward bookings for Thailand have started to feel the pinch due to the Thai-Cambodian border tensions, according to the Tourism Authority of Thailand (TAT), while Chanthaburi tourism operators reported cancellations from foreign tourists for the remainder of the year. Tourism operators urged the government to offer relief measures for affected businesses in the seven border provinces, such as tax reductions. While the border dispute eased following a meeting of the Thai-Cambodian General Border Committee in Malaysia, the tourism outlook in the border provinces remains uncertain. TAT governor Thapanee Kiatphaibool said data from ForwardKeys, an air traffic data company, showed forward bookings for flights in August slowed due to the border skirmishes. As of July 29, bookings for August were down 2.7% year-on-year from 675,551 bookings during the corresponding period in 2024. On July 21, before the border clashes, bookings for August indicated a 0.4% uptick to 564,281. Regarding domestic tourism, she said the 300,000 privileges for major tourism cities under the co-payment scheme were fully redeemed. For the overall scheme, 406,326 of the 500,000 total privileges have been booked, with 93,570 privileges for second-tier provinces remaining. Poompat Tangcharoensiri, president of the Chanthaburi Tourism Association, said European tourists planning to visit the province from September to December have already cancelled their plans. He said tourists feared for their safety, although prime beach destinations and the city district are located 60-70 kilometres and 40km from the border, respectively, while locals continue with their daily lives in the city as usual. The best-case scenario sees average occupancy in Chanthaburi of 40% in August, particularly for hotels located near the beach, said Mr Poompat. However, most hotels are expected to record only 20-30% occupancy for the month. Bookings for the upcoming Mother's Day should pick up, but may severely drop after the holiday passes, he said. "The government and the province have failed to effectively publicise the practices that locals and tourists can follow in Chanthaburi during martial law," said Mr Poompat. On Monday, the association, the Tourism Council of Chanthaburi and the TAT's Chanthaburi office held a meeting on how to stimulate tourism and help operators in the province, he said. They suggested relief measures, such as offering annual tax reductions for employees and tourism operators in Chanthaburi and six other border provinces. These proposals will be submitted to the provincial joint public-private consultative committee later this month, said Mr Poompat. Chatchaipat Sararam, president of the Tourism Council of Buri Ram, said tourists avoided the province, resulting in only 10% occupancy. He said hotels in the Muang district are still open and receiving some locals who evacuated from risk areas near the border to seek temporary stays. Hotels are offering heavy room discounts to help them, while also reducing staff working hours to save on costs. Mr Chatchaipat said guest numbers should increase next week if locals return home for the Mother's Day holiday, while the province is holding events to boost tourism and spending. The border dispute has affected sports tourism in Buri Ram, as sports fans have delayed their plans to visit the province, he said. Mr Chatchaipat said the government should lift domestic travel through tax incentives for visiting or holding meetings in the border provinces.
