German tier 1 supplier ZF will introduce the next generation of its range extender technology for electric vehicles (EVs), with volume production beginning in 2026.

A range extender combines a combustion-powered generator with an electric motor, producing energy for the vehicle battery once its charge drops.

Dr Otmar Scharrer, Senior Vice President R&D, Electrified Powertrain Technology at ZF, said, "Although the all-electric range of passenger cars is around 500 km on average, range anxiety still influences a wide range of buyers when choosing their next vehicle. These (range extenders) represent a real alternative to larger – and thus more expensive – batteries or plug-in hybrids."

The German supplier has gained experience with range extenders, including supplying systems for the iconic London taxi. Now, it is advancing the technology with two new systems: the electric Range Extender (eRE) and electric Range Extender plus (eRE+).

Both designs are highly integrated and flexible across performance levels, 400V or 800V architectures and semiconductor types. The eRE combines an electric motor, integrated inverter, dedicated software and a planetary gearset. The eRE+ adds an intelligent clutch and differential, enabling it to serve as a generator or a secondary drive. Output is scalable: 70–110 kW for the eRE and 70–150 kW for the eRE+.

Dr Scharrer, added, "The new interest and the increased demand for range extenders shows that the potential of this technology is far from exhausted – in particular for model platforms that are already designed for battery-electric drivelines. Behind our solutions is a system and platform concept. This means that we are optimally equipped to respond to all customer and market requirements with shorter development cycles."

Compared to plug-in hybrids (PHEVs), range extenders offer lower additional costs, faster development, simpler platform integration and easier supply chain management — especially attractive for newer automakers with little combustion engine expertise.

China is currently leading with ‘Range Extended Electric Vehicles’ (REEVs) covering over 700 kilometres, thanks to such technology.

"This is where we find it convenient that there is a wide range of BEV platforms that can be supplemented by range extenders," said Scharrer.

The company is also seeing growing interest in the U.S. and European market.

"The market for all-electric vehicles has not developed as much as predicted a few years ago," Scharrer observed. "For this intermediate phase, range extenders can be the ideal solution."

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BorgWarner has secured a new contract to supply its torque-on-demand transfer case with mechanical lock (Mlock TOD) for a full-size SUV developed by a Chinese automaker. Production is scheduled to commence in the final quarter of 2026.

The growing full-size SUV segment increasingly demands vehicles adept at varied terrains, yet traditional part-time systems often require manual mode selection, hindering adaptability. The Mlock TOD addresses this by offering intelligent torque distribution and enhanced convenience, effectively bridging on-road and off-road requirements.

Built upon a proven design, the Mlock TOD integrates torque-on-demand and mechanical lock functions to boost performance and offer flexible solutions across platforms. Leveraging its deep expertise, local production and market insight, BorgWarner remains committed to delivering reliable, high-efficiency drivetrain systems.

Henk Vanthournout, Vice President of BorgWarner Inc. and President and General Manager, Drivetrain and Morse Systems, said, “We have built a 20-year relationship with this customer and we’re proud to continue supplying our AWD technology for their newest SUV. The Mlock TOD featured in this programme combines torque-on-demand four-wheel drive with mechanical lock modes, helping address a wide range of driving conditions while enhancing off-road capability, handling and safety. As a leader in four-wheel drive technology, BorgWarner will continue to leverage its proven product portfolio and technical expertise to deliver greater value to customers.”

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BorgWarner has secured a new dual-clutch transmission (DCT) programme with a Chinese motorcycle manufacturer, with production scheduled to begin in the third quarter of 2027. The integrated systems solution encompasses dual clutches, hydraulic control modules and clutch control software, designed for two-wheeled motorcycles and four-wheeled vehicles featuring engine displacements above 500 cc.

As the motorcycle industry increasingly embraces automatic shifting, dual-clutch technology is drawing growing market interest over automated manual transmission (AMT) and continuously variable transmission (CVT) alternatives. Dual-clutch systems offer superior shift smoothness and higher power transmission efficiency, making them particularly well-suited for larger-displacement performance motorcycles where responsive and seamless gear changes are essential.

With nearly 10 million passenger car dual-clutch units delivered globally, BorgWarner brings proven engineering expertise and mature manufacturing capabilities to the two-wheeler segment. This programme reflects the company's evolution from a component supplier to a system-level partner, combining hardware and software to support the customer's domestic growth in China while facilitating expansion into Europe, North America and other international markets.

Henk Vanthournout, Vice President of BorgWarner Inc. and President and General Manager, Drivetrain and Morse Systems, said, “Passenger car transmission technology provides a strong reference point for the evolution of motorcycle automatic transmissions, and we believe automatic transmission technology will continue to gain momentum in the motorcycle market. With our proven DCT expertise and systems integration capabilities, BorgWarner is well positioned to support our Chinese motorcycle customer in bringing its DCT solution to production and advancing automatic transmission technology for motorcycle applications.”

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Tier 1 component supplier Sona BLW Precision Forgings (Sona Comstar) has announced its financial results for Q1 FY2027, reporting revenue of INR 13.10 billion, representing a 54 percent YoY growth. EBITDA reached INR 3.03 billion with a margin of 23.1 percent, while profit after tax stood at INR 1.81 billion.

Interestingly, battery electric vehicle revenue reached an all-time high of 44 percent of total revenue, growing by 107 percent YoY.

During the quarter, the company unveiled its Sona Comstar 2.0 strategy and announced its entry into the robotics and physical AI sector, alongside expansion into high-voltage electric and hybrid powertrain systems through a partnership with DENSO Corporation.

Vivek Vikram Singh, MD & Group CEO, commented: “Q1 FY27 marks the unveiling of Sona Comstar 2.0 – our ambition to grow tenfold again over the next decade. As part of this strategy, we announced our entry into Robotics and Physical AI. Our partnership with DENSO also takes us into high-voltage electric and hybrid powertrain systems, completing an important missing piece in our electrification portfolio. The quarter was equally strong financially. We delivered our highest-ever quarterly revenue, BEV revenue and BEV revenue share. Revenue grew by 54 percent YoY, while EBITDA and PAT increased by 49 percent and 45 percent, respectively. BEV revenue more than doubled, and its share of automotive revenue reached an all-time high of 44 percent, despite continued weakness in the US EV market. This demonstrates the increasing diversification of our EV business across customers, products and geographies. We also secured new business across EV, hybrid and ICE powertrains, spanning India, Europe and North America and nearly every product category in which we operate.”

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Schaeffler India has reported its financial results for Q2 and H1 ended CY2026. Revenue from operations for the quarter was INR 26.81 billion, marking a 17.5 percent increase compared to the corresponding period of 2025, while net profit reached INR 3.36 billion.

For H1 CY2026, revenue from operations was INR 51.88 billion, up 18.1 percent YoY, with a net profit of INR 6.56 billion led by growth in the Automotive Technologies, Vehicle Lifetime Solutions and Intercompany Exports segments.

Harsha Kadam, Managing Director and Chief Executive Officer, Schaeffler India, said, “Schaeffler India registered a strong growth of 18.1 percent for the first half of the year. Our Automotive Technologies, Vehicle Lifetime Solutions and Intercompany Exports business continued the double-digit growth trajectory. Even for the quarter, despite a challenging market we recorded a 7 percent QoQ growth. Quality of earnings marginally impacted given cost pressures due to geopolitical developments. Overall, I am happy to share that we delivered on our financial performance consistently, amid volatility in a very dynamic macro-economic landscape. We remain committed on maintaining the momentum for the remainder of the year.”

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