Mahle says it is accelerating the electrification of road transportation with the upcoming launch of its new range-extender system for heavy electric (BEV) trucks and its Mahle Contactless Transmitter (MCT) electric motor developed for use on the electric drive axles of heavy commercial vehicles.

The company will present its technologies at IAA Transportation, which is to be held in Hannover from September 15 to 20.

Range-extender system

Range extender electric trucks combine the sustainability of electric drive systems with the flexibility and range of the internal combustion engine (ICE). “Time and energy are limited, valuable resources, especially in road transport business; only operators who work economically can survive,” said Arnd Franz, chairman of the group management board and CEO of Mahle. “With electrification products, Mahle can help make heavy trucks more efficient and flexible at the same time as reducing operating expenses.”

The key component of the new system is an efficient high-voltage generator with a continuous output of 110kW and a peak output of up to 130kW, driven by a compact ICE. The high-voltage generator supplies reliable power to the electric drive system even on difficult trips with a full load. Its architecture can be adapted easily to the performance requirements of a variety of applications and regional markets.

Featuring a newly developed advanced oil cooling system, the generator has a power density of more than 7kW per kilogram, allowing a high power output with reduced weight and simplified interfaces.

The system is a self-contained unit integrating a generator, ICE, thermal and fluid management systems, fuel tank, AdBlue tank and exhaust aftertreatment. Designed to fit within the battery installation space of a battery-electric truck, it can be integrated into existing BEV platforms while replacing around one-third of the battery capacity. According to Mahle, this reduces rear axle load by approximately 400kg and overall vehicle weight by around 600kg. The company says the configuration enables a driving range of more than 800km, with roughly half provided by the battery and the remainder by the range extender.

Under real-life operating conditions, the truck emits about 80% less CO₂ in range-extender operation than a truck with a conventional drive system. If the ICE, which is biofuel-ready, is operated with renewable fuels such as the advanced HVO100 bio-diesel, the truck has virtually zero CO₂ emissions.

A comprehensive thermal management system with 48kW of high-temperature and 15kW of low-temperature cooling capacity ensures stable operation of the range extender system under heavy-duty operating conditions. For the ICE engine, Mahle has continued the development of components to reduce fuel consumption and operating costs.

“Our range extender is the key to disconnecting the market ramp-up of battery-electric trucks from the inadequate pace of infrastructure development,” said Dr Marco Warth, the vice president of Mahle Corporate Research and Advanced Engineering. “If the charging station is busy, or alternative routes are called for as a result of weather conditions or congestion, and infrastructure reaches its limits, other fleets can be stranded; an e-truck with range extender just carries on. Operational availability is maintained, even under peak conditions.”

MCT electric motor for heavy commercial vehicles

The MCT electric motor was developed for use on the electric drive axles of heavy commercial vehicles. It is not equipped with permanent magnets and therefore does not require any rare earth elements. Compared with a benchmark permanent magnet synchronous motor (PMSM), the MCT electric motor saves up to 3kg of rare earth magnets per vehicle. The elimination of rare earth magnets reduces the environmental footprint of the electric drive system.

In real-life driving conditions, the new motor is 10% lighter and more efficient than permanently excited electric motors with magnets. Compared with the permanently excited variant, it reportedly offers higher efficiency within a significantly larger operating envelope covering a variety of driving situations. The MCT electric motor has a peak output of 370kW and torque of over 900Nm at 3,900rpm. The motor efficiency in the VECTO cycle, an EU simulation tool for determining the fuel efficiency of new vehicles, is about 95%.

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Molicel has launched the INR-21700-P70X cell, part of its PX series, to “bridge the gap” between lithium-ion batteries and supercapacitors, the company said. The cell has a stated capacity of 7,000mAh, energy density of 340Wh/kg and continuous discharge rate of up to 30C.

Molicel’s cells have previously been used in performance-focused projects such as the McMurtry Spéirling electric hypercar.

The cell was launched at the Advanced Automotive Battery Conference (AABC) Europe 2026 and comes as BEV growth slows and auto makers increasingly shift investment toward hybrid models. In its 2026 outlook, the International Energy Agency (IEA) highlights this shift, noting that manufacturers are actively prioritizing hybrids. In response, a surge in hybrid demand is redefining key regions: in the USA, hybrids neared 20% of new vehicle sales volume by late 2025 according to CNBC, while in Europe, they captured a 24% market share based on International Council on Clean Transportation (ICCT) data.

Concurrently, the Asia-Pacific region asserted its market dominance, capturing 51.67% of the global hybrid vehicle market value across all segments, including mild, full and plug-in hybrids. The multi-regional momentum is propelling the global hybrid vehicle market from US$335.21bn in 2026 to a projected US$570.78bn by 2034.

This market shift is changing battery requirements for next-generation hybrid vehicles, which demand both high energy density and high power output. According to Molicel, the INR-21700-P70X has been designed to address these requirements, delivering a peak power output of 900W for up to five seconds to support rapid acceleration, such as during overtaking, while also enabling high-power energy recovery under heavy regenerative braking.

The company also states that the cell can transition to high-power output in under 200µs, providing a response comparable to a supercapacitor and supporting repeated high-frequency power pulses with minimal performance degradation.

“The global automotive landscape is undergoing a profound diversification, where the demand for immediate, high-frequency burst power has become paramount,” said Casey Shiue, president of Molicel. “Our next-generation PX series isn’t just an evolutionary upgrade; by blending supercapacitor-like responsiveness with the high energy density of lithium-ion, we are redefining what hybrid powertrains can achieve in terms of raw power, safety and lifespan.”

The INR-21700-P70X has passed the UL9540A thermal runaway evaluation, a widely used safety test for energy storage systems. The company attributes the cell’s performance to its single-crystal cathode technology, which it says reduces exothermic heat generation by nearly 50% compared with conventional polycrystalline materials.

Molicel also stated  that, during abuse testing, the cells emitted smoke rather than undergoing an immediate catastrophic rupture, helping to delay thermal propagation. The company said these characteristics are intended to enhance safety in applications ranging from data center battery backup units (BBUs) to next-generation hybrid electric vehicles (HEVs).

Furthermore, unlike BEVs that undergo deep daily cycles, hybrids subject batteries to hundreds of thousands of rapid, shallow fluctuations. In testing mimicking this environment under a supercapacitor profile, Molicel’s PX series retained 96% capacity after 1,000,000 cycles (+10C for 10s/-2C for 110s, cut-off temperature 83°C).

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Volkswagen has unveiled the ID Cross, an all-electric compact SUV built on the MEB+ platform, the latest iteration of the auto maker’s modular electric drive. The vehicle will be offered with three motor outputs (85kW/114hp, 99kW/133hp and 155kW/208hp) and two battery sizes (37kWh LFP and 52kWh NMC), with a WLTP range of up to 427km. DC fast charging from 10-80% takes roughly 23 minutes for the smaller batter and 24 minutes for the larger one. The car uses VW’s new Innovision infotainment system.

Thomas Schäfer, CEO of the Volkswagen brand, head of the Brand Group Core and member of the group board of management, said, “The ID Cross brings together technological expertise, clean design, impressive, intricate solutions and genuine all-rounder qualities – all for excellent value for money. These are ideal conditions for a new success story from Volkswagen.”

The ID Cross measures 4,153mm long, 1,581mm tall and 1,794mm wide, with a 2,601mm wheelbase. The MEB+ platform gives it more interior and cargo space than the combustion-engine T-Cross, offering 475 liters of trunk space, 20 liters more than the T-Cross, including additional storage under the variable boot floor. The car also has a 25-liter front storage compartment.

The ID Cross places the Digital Cockpit Pro, a 26cm/10.25in driver display, and the 32.8cm infotainment touchscreen along a single horizontal line. Pressing the view button on the steering wheel activates a retro display mode styled after the Golf Mk1, showing a classic-style speedometer and a right-hand gauge that displays energy output/consumption rather than engine RPM, styled as a powermeter. Modern functions like dynamic road sign display are integrated into this retro layout as well.

The vehicle includes driver-assist systems as standard, with next-generation Travel Assist available as an option. Because the optional system uses online data, VW has renamed it Connected Travel Assist. It’s able to detect red traffic lights and can automatically bring the car to a stop, within the system’s limits. The car also offers One Pedal Driving, which decelerates the vehicle using only the accelerator pedal. Smart parking aids that make maneuvering even easier are also available.

Particular attention was paid to ride comfort and driving stability when developing the ID Cross. The suspension specially tuned for the electric front-wheel drive combines precise and safe handling with high long-distance comfort, said VW, and the high-quality dampers, comfort-optimized suspension components and numerous measures to reduce noise and vibrations ensure a “pleasantly quiet driving experience”. In addition, there is direct steering response and a finely tuned brake system that impresses with a natural pedal feel.

The ID Cross is offered in Germany in three trim levels. The base Trend trim includes standard 90kW DC fast charging. The Life trim adds 18in alloy wheels, dual-zone automatic climate control, adaptive cruise control, a rear-view camera and a junction assistant. The top Style trim adds IQ.Light LED matrix headlamps with an illuminated light strip, 3D LED rear lights, illuminated VW logos, heated seats and steering wheel, personalized interior trim and keyless start/locking.

The ID Cross offers optional features not available on the T-Cross or, Volkswagen said, on several competitors in the segment. These include a 425W Harman Kardon sound system with 10 speakers and a subwoofer, and a pneumatic massage function for the electrically adjustable 12-way front seats, with three selectable massage programs. A 74 x 90cm panoramic roof can also be integrated, which extends into the rear of the cabin, with an electric sunshade for dimming.

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Cupra has appeared at the 2026 Festival of Speed with a range of motorsport and road car announcements, including an extended partnership with Kiro for its Formula E program, the debut of the new Cupra Leon VZ e-Hybrid Racer, the Gen4 Formula E car and the fully electric Raval in right-hand drive. The company positions motorsport as a development platform for its road-car technology.

Formula E

After two successful seasons together, Cupra has extended its Spanish-American partnership with Silverstone-based Kiro Race. The agreement will see Cupra Kiro continue competing together in the ABB FIA Formula E World Championship. The team is set to enter the new Gen4 era of Formula E with the latest Porsche 975 RSE.

At the Goodwood Festival of Speed 2026, Cupra Kiro will unveil its Gen4 Formula E car in a striking Energy Flow livery created exclusively for the event.

Season 13 of Formula E introduces the Gen4 regulations, delivering the fastest and most advanced Formula E cars to date. Power increases to 600kW (816ps), while permanent active all-wheel drive (AWD) enhances performance and efficiency. The Gen4 car will exceed 335km/h and accelerate from 0-100km/h in just 1.8 seconds.

British driver Dan Ticktum will take the championship’s new-generation display car up the famous 1.87km Goodwood Hillclimb on Sunday.

 From street to racetrack

The second pillar of Cupra’s Festival of Speed debut is the Cupra Leon VZ e-Hybrid Racer. Finished in a matching livery, it draws inspiration from Formula E, offering, the company says, a compelling vision of the future of touring-car racing.

The Leon VZ e-Hybrid Racer is a Cupra concept car combining an electric motor (from the Raval), combustion engine (from the Leon VZ) and battery tech (from the Leon PHEV). It’s positioned as a test vehicle exploring a hybrid racing format that blends ETCR-style electric boost strategy with the lower cost and established tech of traditional touring car racing.

The Leon VZ e-Hybrid Racer is designed for sprint-format wheel-to-wheel racing. Drivers must manage tire wear, power delivery and energy use during races.

The e-Hybrid racing prototype produces up to 370kW (500ps) combined output: a 2.0-liter combustion engine (250kW) plus a rear electric motor (120kW) paired with a 6-speed sequential paddle-shift gearbox. Cupra states 0-100km/h in 3.8 seconds and a top speed of 265km/h.

Cupra Raval

The right-hand-drive Cupra Raval will launch in the UK in summer 2026, with a maximum range of up to 450km, depending on trim and battery.

The Cupra Raval is a 4m-long hatchback, designed, developed and produced in Barcelona and named after the city’s Raval neighborhood. It’s built on the Volkswagen Group’s new MEB+ platform, shared across the group’s Electric Urban Car family.

All Raval models feature a sport chassis lowered by 15mm, tuned suspension, progressive steering and ESC sport (electronic stability control). The Raval VZ produces 166kW (226hp) and adds 19in alloy wheels, electric memory bucket seats in vegan leather, matrix LED headlights, DCC sport suspension and an electronic limited-slip differential. The Raval is available in multiple trims and colors, with ambient lighting and door projections running on Android OS.

In related news, MG announces roadmap focusing on Plug-in Hybrid+ and SolidCore Battery

The new Polestar 4 SUV builds on the success of the Polestar 4 Coupe, offering an added layer of flexibility and practicality, with versatile storage capabilities for every journey, while retaining the design, performance and sustainability credentials that define the coupe.

Michael Lohscheller, Polestar CEO, said, “Polestar 4 has quickly established itself as a favourite among our customers, and we’ve seen strong demand from drivers who want distinctive design and performance combined with great practicality.

“With Polestar 4 SUV, we’re building on that success by offering even more versatility, while staying true to the Polestar 4 character. Wrapped in a stunning design, this is a car I’ve been looking forward to sharing with the world.”

The Polestar 4 SUV and Coupe feature retuned chassis components aimed at improving driving dynamics. The 400V architecture delivers a range of up to 630km (WLTP) in rear motor variants and up to 544hp in dual motor models.

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Building on more than a century of innovation, MG has unveiled its latest technology roadmap, outlining how the brand will continue to bring advanced electrification and intelligent driving technologies to a wider audience.

Focusing on powertrain and ADAS development, the roadmap focuses on the next-generation MG Plug-in Hybrid+ technology and the introduction of MG SolidCore Battery technology for Plug-in Hybrid+ models.

New Plug-in Hybrid+ technology 

The Plug-in Hybrid+ system is built around a new generation of dedicated hybrid petrol engines, available in 1.1-liter and 1.5-liter turbocharged variants, achieving maximum thermal efficiencies of more than 42% and 43% respectively.

The engines work in conjunction with a new hybrid transmission incorporating two core technologies: power split and motor decoupling, designed to optimize fuel and electrical energy efficiency.

Power Split technology distributes power between the engine and electric motors, continuously adjusting energy flow according to driving conditions to enable the powertrain to operate efficiently without the constraints of a fixed-ratio transmission. Motor decoupling introduces a disconnect mechanism that isolates the generator during pure electric driving, reducing drag and improving electric drive efficiency.

The Plug-in Hybrid+ system automatically selects the the optimum operating mode across the full speed range, using electric drive at low speeds, power split operation at medium speeds and direct engine drive at higher speeds. This operating strategy is designed to maintain engine thermal efficiency above 40% across approximately 90% of driving conditions, while achieving up to 90% electric drive efficiency regardless of battery charge level.

The powertrain accelerates from 0-62mph in under six seconds, with 50-75mph acceleration taking as little as 3.5 seconds. Torque delivery has also been revised, with hill-start capability improved by up to 72% compared with the previous system.

By eliminating generator idling during pure electric driving, Motor Decoupling technology reduces noise, vibration and harshness by up to 5dB in EV mode compared with conventional plug-in hybrid systems.

Plug-in Hybrid+ models will also benefit from this new technology, beginning in 2027 with the launch of the MG ZS Plug-in Hybrid+.

SolidCore battery for Plug-in Hybrid+ models

MG has confirmed that its SolidCore Battery technology will be introduced across future Plug-in Hybrid+ models.

Built around a semi-solid-state architecture incorporating a 3D spinel structure, the SolidCore Battery delivers higher energy conversion efficiency and faster power response than conventional liquid-electrolyte batteries, MG said, adding that it is optimized for Plug-in Hybrid+ applications, offering more consistent power delivery, improved range stability and more stable performance across varying speeds, driving scenarios and climate conditions.

By maintaining stable battery output across a range of operating conditions, the SolidCore Battery technology supports more consistent vehicle performance regardless of speed, driving scenario or ambient temperature, contributing to the overall efficiency of the Plug-in Hybrid+ system, MG said.

The SolidCore Battery technology reduces the impact of low temperatures and depleted battery charge on vehicle performance, addressing some of the limitations commonly associated with plug-in hybrid vehicles.

The first MG Plug-in Hybrid+ models to feature SolidCore Battery technology will be three new SUVs in the B, C and D segment categories.

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Following the introduction of a 75kWh version earlier this year, Nissan has announced a new 52kWh battery option for its UK-built, all-electric Leaf.

The new battery option, available on Engage and Advance grades, offers a range of up to 280 miles on a single charge (WLTP) and one of the highest miles-per-kWh ratios of any EV currently on sale in the UK.

Aditya Moorthy, product marketing manager at Nissan Motor GB, said, “We are excited to introduce the new 52kWh battery option on the All-New Nissan Leaf, offering up to 280 miles of range (WLTP). Designed for everyday driving, it combines confident electric performance with the comfort, technology and practicality customers expect from Leaf.”

Related news, Renault 4 E-Tech Plein Sud E V completes 1,000-mile UK journey

A Renault 4 E-Tech electric Plein Sud has completed the Easee Sun Run, a 1,000-mile journey from Land’s End to John O’Groats powered only by solar energy. Timed around the summer solstice, the journey set out to follow the sun across the length of the UK.

A solar story across the UK

The charging stops on the route illustrated the breadth of solar adoption in the UK. Roskilly’s Ice Cream in Cornwall has solar panels that contribute to the business’s daily energy. Chard Junction, where the Renault 4 E-Tech electric charged for the first time since leaving Land’s End, is home to the UK’s oldest commercial solar farm. Further north in Derbyshire, Whaley Bridge Cricket Club uses solar power to operate entirely off-grid.

At Swansea University, Power Roll is developing rollable solar films that are lightweight, flexible and designed to bring photovoltaic technology to surfaces and spaces that traditional panels can’t reach. In Durham, researchers are working on ultra-efficient vehicles capable of running directly on energy from the sun, turning solar power from something stored into something immediate.

In Scotland, the route highlighted further applications of solar technology: a solar pyramid south of Edinburgh illustrates how the technology has evolved, while on the east coast, homes and businesses are using solar generation combined with battery storage to operate independently of the grid.

Brought together by one journey 

The Renault 4 E-Tech completed the journey in its open-top canvas roof configuration, its 52kWh battery and 150hp powertrain powered throughout by solar-sourced electricity. That energy came from a combination of established solar installations and portable solar-charged storage, delivered via a Charge Pro three-phase EV charger provided by Easee at key points along the route, enabling the full length of the UK to be driven without drawing electricity from the grid.

Project leader Jeremy Hart said, “You set out thinking this is about getting from one end of the country to the other, but it quickly becomes about everything in between. One stop is a solar farm doing exactly what you’d expect, the next is a cricket club running itself off grid, then you’re looking at research that could change how solar works altogether. Each stop adds something different, and by the time you reach the end, you realize the car has been picking up that same energy all along and quietly turning it into miles.”

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Shell has unveiled the Triple 10 Challenge concept car, a proof-of-concept vehicle designed to “inspire a new design philosophy for the next generation of battery electric vehicles”.

The compact, mass-market EV demonstrates next-generation electric vehicle capability and offers the industry an alternative to the current reliance on ever-larger batteries by re-imagining the fundamentals of thermal management.

The vehicle meets three ambitious goals that Shell believes can help drive the future of mass-market electric mobility: a sub 10-minute charge time, 10km/kWh economy and a lifecycle 10-metric ton CO2e footprint. These are achieved using Shell’s advanced thermal fluids to achieve optimized thermal management.

The Challenge demonstrates the potential of a simplified, single-circuit cooling architecture to manage the thermal load of the car’s powertrain under extreme fast-charging scenarios in real-world conditions, Shell said.

Cara Tredget, VP mobility and lubricants technology for Shell, said, “With the Triple 10 Challenge concept car, we have unlocked the potential for faster charging, lighter systems and improved lifecycle efficiency by using our advanced thermal fluids. Together with our co-engineering partners, we are proud to develop alternative options for sustainable EV development, leveraging technologies that are available today and are scalable to support customers into the future.”

The concept car has been designed to achieve 10km/kWh in driving economy with a smaller, more efficient battery system, with a more than 30% improvement in overall energy efficiency compared with many current-generation EVs.

The vehicle can charge its battery from 10% to 80% in 9 minutes and 54 seconds, while maintaining thermal stability and battery longevity, according to the company. Unlike many ultra-fast-charging EVs that require chargers rated above 300kW, the vehicle achieves this performance using a standard 175kW charger available on existing charging networks.

At this charging rate, the vehicle adds up to 24km of driving range per minute, compared with an average of 13km per minute for typical battery-electric vehicles using the same charger – nearly 90% more range added per minute of charging.

The concept car is estimated to have a lifecycle carbon footprint of approximately 10 metric tons CO2e. Enabled by its lightweight design, optimized battery capacity, low-carbon and recyclable materials, together with 100% renewable electricity for vehicle charging, this is estimated to represent around a 50% reduction in lifecycle emissions compared to typical battery electric vehicles in the European market.

Immersive thermal management: Shell Recharge

Unlike traditional cooling systems that use water-glycol, Shell’s Recharge dielectric fluid enables direct immersion cooling of the battery and indirect cooling of the powertrain components, including the motor and power electronics. By redefining heat management across the battery and powertrain, the team has unlocked the potential for faster charging, lighter systems and improved lifecycle efficiency.

By incorporating a more compact and efficient battery pack design with fewer modules and using Shell’s advanced thermal fluid, enabling a simplified housing architecture, these improvements contribute to about a 25% reduction in overall battery pack cost compared to a conventional EV.

Related news, Superlight secures US$21m for middle-mile EV featuring fully digital powertrain

Superlight has raised an oversubscribed US$21m series A round, co-led by Engine Ventures and 2150, that brings the company’s total capital raised to US$33m. Superlight plans to use the proceeds to complete its UK manufacturing facility, support initial sales in the UK and EU, and develop homologated vehicles for customer testing and entry into the US market.

Demand for middle-mile logistics, the movement of goods between regional distribution centers and local sorting facilities, is growing rapidly with the global market projected to reach US$137.97bn by 2026. Rising consumer expectations for overnight delivery are pushing distribution networks closer to urban areas, increasing the need for efficient freight transportation. As a result, maximizing cargo capacity, cost efficiency and delivery performance has become increasingly important.

Despite this growth, innovation in the middle-mile segment has lagged behind other areas of commercial transportation – and Superlight is addressing this by developing an electric commercial vehicle specifically designed for middle-mile logistics. Its OV-1 vehicle features a modular, customizable platform built on a clean-sheet architecture, with a fully digital powertrain and aerospace-inspired engineering principles.

According to the company, the vehicle delivers 50% more cargo capacity while using 50% less energy than comparable 7.5-metric ton trucks. Superlight also states that the OV-1 can reduce energy costs per pallet-kilometer by 73% and requires only one-tenth of the capital investment typically associated with conventional truck manufacturing.

“By harnessing the inherent advantages of electric propulsion and software-centric manufacturing, we’re flipping the economics of commercial EVs, unlocking massive cost savings that also happen to provide significant environmental benefits,” said Noamaan Siddiqi, co-founder and CEO of Superlight.

“Our purpose-built EV platform enables transformative performance and safety advantages that can’t be duplicated by retrofitting electric into legacy trucks. And unlike many manufacturers, Superlight owns the entire chain of designing, building and delivering its EVs, which allows us to provide unique vehicle features to continually optimize for innovation and efficiency.”

Superlight has accumilated 500,000km of powertrain mileage, including with commercial pilots of OV-1 in the UK by major e-commerce and ground handling providers.

Superlight’s production system is designed to be digital-first and AI-native, built around two core capabilities. The first, SuperVisor, is a digital twin of the company’s factory that uses real-time production data to monitor shop-floor operations, support continuous improvement, and identify potential quality issues before they occur.

The second, Autonomous Logistics & Integrated Service, is a predictive maintenance and fleet management platform that uses data from sensors installed on OV-1 vehicles to optimize vehicle performance, improve maintenance planning and support more efficient driver operations.

“Superlight is on a mission to modernize commercial trucks, a crucial component of modern society that has experienced surprisingly little innovation in nearly a century,” said Israel Ruiz, president and general partner at Engine Ventures.

“By replacing legacy manufacturing and driving mechanics with a new architecture, the company has an opportunity to deliver massive performance, safety, efficiency and cost improvements to brands, fleet owners and transportation companies, while at the same time wiping out particulate matter emissions.”

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