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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Tier 1 supplier Uno Minda has announced that its Board of Directors has approved setting up of a greenfield manufacturing facility for aluminium die casting in Sambhaji Nagar (Aurangabad), Maharashtra.

The new facility is targeted to meet the growing demand for casting components, particularly in electric two- and four-wheelers. As automakers look to introduce alternative energy vehicles with higher energy efficiency, lightweighting becomes a critical focus area. This is an area where aluminium die casting has emerged as a critical requirement for lightweight, high-performance vehicle platforms. EVs fundamentally require significantly more aluminium-based structural and thermal components compared to their internal combustion counterparts—making advanced die casting capabilities central to EV powertrain and body applications.

In addition, the upcoming facility will play vital role in supporting Uno Minda’s backward integration strategy by supplying essential casting components to its forthcoming four-wheeler electric vehicle powertrain plant.

The new project involves a total planned capital investment of approximately INR 2.1 billion, to be implemented in a phased manner over the next five years. The investment will be funded through a balanced mix of internal accruals and debt. Phase 1 of the plant is expected to commence commercial operations by Q2 FY27.

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German private equity investor Mutares SE & Co is set to acquire Continental’s drum brakes production and R&D location in Cairo Montenotte (Italy) as part of its new platform investment in the automotive and mobility segment.

This follows the Continental Group’s recent announcement to spin off its automotive business as an independent company, Aumovio in September 2025.

As per the understanding, Mutares will take over all employees and business activities related to Continental’s drum brake business in Cairo Montenotte. This is expected to add about EUR 100 million in revenue for the company in 2025. The facility in Cairo Montenotte, Italy, is a production and R&D site for hydraulic drum brakes and manufactures products such as the Parking Brake for Simplex Brakes (EPB-Si) and the Drum Brake (Si). It employs around 400 people.

Johannes Laumann, CIO, Mutares, said, “With the acquisition of Continental’s Cairo Montenotte site we are strengthening our automotive and mobility segment. The long-standing expertise, strong product portfolio and highly skilled workforce provide an excellent foundation for operational development and future growth.”

Philipp von Hirschheydt, member of the Continental Executive Board and CEO of the future Aumovio, added, “We are confident that Mutares, with its extensive experience in the automotive business, is the right owner to lead this site into the future. Our shared goal is to ensure continuity for employees, customers and partners while securing long-term prospects for the Cairo Montenotte location.”

“With this agreement, we further consolidate our European manufacturing footprint. Moreover, it marks an important step in our strategy in Europe to better allocate R&D and investments with our product strategy and future technologies, such as electric braking or integrated friction solutions. The transaction deal follows Automotive’s strategy to sharpen our focus on our core business and streamline our business operations,” added Hirschheydt.

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Tier 1 automotive supplier Forvia Hella has announced the appointment of Subramanian Narayanan (Subu) as the new Head of Global Development Center India.

It was in May 2001, Narayanan started his journey in the automotive industry as a Product Designer at Visteon Corporation.

In 2005, Subu joined the Forvia Hella Group (formerly Hella Lighting and Faurecia) and over the course of nearly two decades, he held various positions in the company. Most recently, he was the Head – Technical Center and Program Management.

In his new role, Narayanan will be tasked with leading new product development and technological trends for Forvia Hella.

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Highway Roop Precision Technologies (Highway Roop), a global auto components platform formed by the integration of Highway Industries and Roop Automotives, has appointed Dharmesh Arora as its new Chief Executive Officer.

Arora brings a wealth of experience to Highway Roop, having most recently served as CEO for Asia Pacific at Schaeffler Group for over five years. Prior to that, he held the position of CEO for Schaeffler India for seven years. His extensive career also includes two decades in leadership roles within purchasing and supply chain at General Motors. He started his journey in the automotive sector in 1986 as a Product Engineer at Maruti Suzuki India, making him a seasoned industry veteran.

Mohit Oswal, Non-Executive Chairman of Highway Roop, said, “We are excited that Dharmesh has joined as CEO of Highway Roop. He is a highly experienced professional who has a deep understanding of the automotive industry and brings decades of global experience in building and managing automotive businesses”.

He added that Arora’s focus will be on "accelerating growth, driving operational excellence and leveraging innovation to deliver enhanced value for the Platform’s customers and strengthen its market position."

Dharmesh Arora said, “I am honoured to join Highway Roop at such an exciting time for India’s automotive industry. The platform’s strong manufacturing capabilities, diverse product portfolio, and global customer base create a powerful foundation for expansion.”

Highway Roop is a prominent manufacturer of forged and precision-machined components, including steering system assemblies and various transmission and powertrain applications. The company caters to electric, hybrid, and internal combustion engine (ICE) powered vehicles. The platform has also indicated its intent to acquire synergistic assets as part of its growth and expansion strategy within the auto components sector.

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