In the engine compartment, plastics used for pumps and valves are tested under hydrolysis conditions (water-glycol) to meet the increasing demands of e-mobility. The Arrhenius equation enables reliable extrapolation of the service life of plastic components - such as Ultramid® polyamide with enhanced hydrolysis resistance, glass fiber reinforcement, and low halogen content - to over 100,000 hours. This ensures that, as in this case, the required 45,000 to 55,000 operating hours are achieved.

German chemical major BASF has announced the results of long-term material testing that predicts a service life exceeding 100,000 hours for its latest generation of polyamides used in electric vehicles (EVs).

The shift toward e-mobility has increased durability requirements for plastic components under the bonnet, with components now requiring a lifespan of 45,000 to 55,000 hours, compared to 5,000 hours for internal combustion engines (ICE).

The increase in required service life is driven by battery charging processes that require constant temperature regulation. To verify performance, BASF transitioned from standard air-heat testing to hydrolysis storage, which involves ageing materials in water-glycol mixtures. The company employs the Arrhenius equation to determine the relationship between temperature and reaction rate, allowing for the extrapolation of service life under standard operating conditions.

The material tested, Ultramid, features glass fibre reinforcement and a low halogen content. Testing initiated in August 2020 indicates that the hydrolysis resistance of this polyamide allows it to maintain its properties for over 100,000 hours. These components are typically utilised in vehicle pumps and valves.

The data provides the automotive and haulage sectors with verification that plastic components can withstand the chemical and thermal demands of long-term EV operation.

Catena-X Automotive Network, a non-commercial organisation, has identified three shifts in data exchange that are expected to define the global automotive industry in 2026. The association reports that data collaboration is becoming a board-level priority and a prerequisite for trade as eight of the world’s top ten suppliers join the ecosystem.

The association brings together a coalition of OEMs, suppliers, technology providers, and industry bodies, including ADAC, AIAG, BMW, Mercedes-Benz, Porsche, Renault, Volkswagen Group companies, Volvo, VDA, TÜV SÜD, Fraunhofer, Amazon Web Services, Huawei, Microsoft and Magna, among others.

Catena-X suggests that data fragmentation is becoming a trade barrier. Regulations such as the Carbon Border Adjustment Mechanism (CBAM) and the EU Digital Battery Passport increase the requirement for product-level evidence. Failure to produce consistent data can result in market exclusion or increased costs.

The association provides standards designed to make documentation reusable across partners. This approach aims to prevent the need for bespoke integrations for every customer, particularly for Tier 2 and Tier 3 suppliers where data readiness varies.

Data management is increasingly competing with R&D and intellectual property for budget allocation. Catena-X warns that compliance costs can rise from 0.05 percent to 2 percent of revenue if reporting remains manual and duplicated.

To address this, the network utilises toolkits such as the Product Carbon Footprint (PCF) framework. Standardised inputs allow sustainability data to be shared across companies, which the association claims is up to five times more efficient than legacy reporting methods.

Software Traceability and Cybersecurity

In 2026, software risks are expected to become a primary trigger for vehicle recalls. As vehicles become software-defined, the ability to trace code lineage and component provenance is necessary for risk management.

Catena-X highlights the Software Bill of Materials (SBOM) as a tool for triage during cyber incidents. Making software versions and dependencies visible across tiers allows for faster responses to security vulnerabilities.

Hanno Focken, Managing Director, Catena-X, said, “We are seeing a major shift in what the industry is being asked to prove. Data is becoming a condition of trade and a real cost-to-serve. At the same time, cyber incidents are increasingly becoming a product recall risk. Work that used to sit in the background is now affecting market access and margins. Catena-X exists to make trusted interoperable exchange practical across every tier of the supply chain, while protecting data sovereignty.”

Valeo has announced that its extended reality (XR) gaming experience will enter series production on the Renault Filante, the flagship vehicle from Renault Korea. The system, titled ‘R:Racing’, is based on the Valeo Racer concept unveiled at SXSW in 2024.

The technology represents the first XR gaming experience integrated into a production vehicle. It utilises existing sensors, cameras and hardware to blend virtual gameplay with the live environment. By synchronising gameplay with vehicle motion, the system is designed to reduce the sensation of motion sickness often associated with in-car screens.

The integration into the Renault Filante demonstrates how software-defined vehicle architectures can repurpose hardware for digital experiences. The system uses real-time data and sensor fusion to create a motion-synchronised experience for passengers.

The Renault Filante, developed and produced in Korea, is a crossover featuring connectivity and digital interfaces. The vehicle serves as the launch platform for Valeo's shift from automotive engineering into immersive cockpit technologies.

Marc Vrecko, CEO, Valeo Brain division, said, “The transition of the original Valeo Racer concept to series production is a clear illustration of how Valeo turns innovation into concrete customer value within a short period of time. Together with Renault Korea, we are redefining the in-car experience by combining perception technologies, software and creativity to make mobility more engaging, without compromising safety.”

Nicolas Paris, CEO, Renault Korea, added, “The Renault Filante embodies our ambition to deliver vehicles that combine emotional design, advanced technology and meaningful digital experiences for our customers. Working closely with Valeo on this world-first XR gaming production feature demonstrates the strength of our partnership and our ability to bring cutting-edge innovation from concept to reality.”

Spanish powertrain major Horse Powertrain and Repsol have announced the development of a hybrid powertrain designed to run on 100 percent renewable petrol. The HORSE H12 Concept engine achieves a peak brake thermal efficiency (BTE) of 44.2 percent and is intended to reduce vehicle fuel consumption.

According to WLTP testing, a vehicle equipped with this powertrain consumes less than 3.3 litres per 100 kilometres, representing a 40 percent reduction compared to 2023 European passenger car averages. When operated with Repsol’s renewable fuel, a mid-size car driving 12,500 kilometres annually emits 1.77 tonnes of CO2 less than a vehicle using traditional combustion technology.

The H12 Concept is an evolution of the HR12 engine and incorporates several engineering updates:

• Combustion System: Features a 17:1 compression ratio.
• Exhaust Management: Utilises a next-generation exhaust gas recirculation (EGR) system and an optimised turbocharger.
• Ignition: Includes a high-energy ignition system.
• Transmission: Features a hybrid gearbox with energy management and lubricants designed by Repsol to reduce internal friction.

Teams from the Horse Technologies Division in Valladolid and the Repsol Technology Lab in Madrid have validated two prototypes. A demonstrator vehicle is scheduled for presentation in early 2026. The companies state that this project is a step towards the industrial production of high-efficiency hybrid engines.

Repsol has commenced industrial-scale production of 100 percent renewable gasoline at its Tarragona facility. This fuel is compatible with existing gasoline engines and is currently distributed at 30 service stations in Spain under the Nexa 95 brand.

Patrice Haettel, COO, Horse Powertrain and CEO at Horse Technologies, said, “The HORSE H12 Concept is an example of how highly efficient engines and renewable fuels can reduce emissions today, without waiting for future solutions. As a company, we believe that relying on a single technology is not the fastest way to cut emissions. This is why we advocate a technology neutral approach that enables innovation across all solutions - electric, hybrid, range extenders and low-carbon fuels.”

Luis Cabra, Deputy CEO, Repsol, added, “This collaboration shows that decarbonisation can be accelerated through innovative and accessible technological solutions. The use of 100 percent renewable fuels is a net zero emission solution, complementary to electric vehicles, for decarbonising the transport sector. Supporting clear and ambitious regulation that drives investment in renewable fuels and highly efficient engines is essential for Europe to reduce transport emissions faster in a more competitive and effective manner.”

German engineering company FEV recently released analysis on the economic efficiency of electrified commercial vehicles, suggesting that range extender architectures (REEV/Hybrid BEV) can reduce total cost of ownership (TCO) compared to diesel trucks.

According to data from FEV’s research programme, TCO can be reduced by up to 33 percent depending on the driving cycle. In long-haul scenarios, the analysis indicates a cost reduction of approximately 14 percent. These figures are based on European usage profiles involving depot charging at industrial electricity rates of 19 cents (INR 20-21) per kilowatt hour.

The study identifies reduced battery size as a primary factor in cost-effectiveness. A REEV truck operates with approximately 280 kWh of battery capacity, compared to the 560 kWh required by purely battery-electric (BEV) long-haul trucks.

The smaller battery allows for overnight charging via 22 kW AC infrastructure, providing enough energy for daily operations without the immediate requirement for megawatt charging stations. This reduces vehicle weight and increases payload capacity.

FEV reports that REEV trucks can be integrated into existing depot structures, reducing investment risks for operators. Beyond costs, the analysis suggests a reduction in global warming potential of up to 82 percent compared to diesel vehicles, depending on the energy mix used.

The company is currently developing demonstrator vehicles to validate these findings and translate the data into market-ready solutions for the commercial vehicle segment.

Dr. Norbert W. Alt, COO, FEV Group, said, “Our analysis clearly shows that the range extender makes electric trucks immediately economically and ecologically viable – without waiting for the widespread expansion of high-performance charging infrastructure. This is precisely what is crucial in long-distance transport.”

“Range extender-based Hybrid BEV trucks offer an immediately available, economically highly attractive solution for electrified long-distance transport. They combine high electric driving ranges with minimal infrastructure requirements – and deliver measurable added value precisely where cost decisions are particularly sensitive,” Dr Alt concluded.