The road to decarbonisation for the commercial vehicle sector is proving to be a complex and challenging journey, with experts highlighting that a straightforward ‘combustion engine ban’ for lorries and other commercial vehicles is far more difficult to implement than for passenger cars.

Following the European Union’s strict CO2 fleet regulations for passenger vehicles, which effectively introduce a ban on combustion engines, stringent greenhouse gas limits are also being rolled out for commercial vehicles.

Experts at the International Vienna Motor Symposium stressed that the industry is racing to develop a wide array of solutions to match the huge diversity of vehicles on the road – from long-distance trucks and small delivery vans to construction and agricultural machinery.

Prof. Bernhard Geringer, Chairman of the International Vienna Motor Symposium, noted that the entire commercial vehicle industry is working on a wide range of solutions needed to match the diversity of vehicle types on the road in view of the developments expected in 2026.

The legislative pressure is intense. Tobias Stoll, a project manager at the Research Institute for Automotive Engineering and Vehicle Engines Stuttgart (FKFS), pointed out that EU legislation stipulates ‘a 45 percent reduction in CO2 emissions by 2030 compared to 2019,’ with manufacturers facing heavy financial penalties for non-compliance.

This has set the industry's course, with Frederik Zohm (pictured above), Chief Technology Officer at MAN Trucks & Bus, expecting ‘major transformations in the commercial vehicle sector by 2030.’

Egon Christ, Chief Strategist at transport and logistics service provider Mosolf, commented: ‘The course has been set.’

However, the existing transport model, especially for long-haul journeys, is heavily reliant on fossil fuels. A typical diesel lorry has a service life of 1.5 million kilometres, often covering up to 200,000 kilometres annually.

Ten years ago, EU forecasts anticipated a dominant role for hydrogen and a minor one for battery-electric trucks. The reality has turned out to be ‘exactly the opposite,’ according to Nils-Erik Meyer, a division manager at Akkodis Germany.

Today, there are only around 10 fuel-cell truck models in the EU, compared to over 40 battery-electric models.

While battery-electric vehicles are currently the most technologically advanced, their widespread use hinges on a massive overhaul of charging infrastructure.

Oliver Hrazdera, site manager at Akkodis Austria, calculated: “For trucks with an electric range of 500 kilometres, the EU needs 2,000 charging points with 650 or 1,000 kilowatts of charging power.”

Batteries, payload and hydrogen’s setbacks

Freight companies prioritise fast turnarounds, which necessitates rapid charging. Dorothea Liebig, a manager at Shell Global Solutions Germany, explained that the maximum charging capacity for trucks ‘is up to eight times higher than for cars.’ She also highlighted the alternative of battery swapping, particularly prevalent in China, where it is ‘fully automated and takes just seven minutes’ at the over 1,200 existing battery replacement stations for trucks.

For many journeys, electric trucks are already viable. Meyer from Akkodis calculated that with a mandatory driver break and recharging, a truck could cover ‘around 630 kilometres are possible in one shift. This covers 90 percent of all journeys.’

However, a key disadvantage of battery-electric lorries is the impact on payload, which is reduced by ‘three to six tonnes for the drive system, mainly due to the batteries,’ according to Meyer. By contrast, hydrogen fuel cells only reduce the payload by one tonne.

Despite this advantage, enthusiasm for fuel cells has cooled in Europe. Markus Heyn, Managing Director of Robert Bosch and Chairman of Bosch Mobility, reported that in Europe and the US, a major hurdle has been the substantial cooling requirements for fuel cells, which need ‘two to two and a half times more cooling surface area than diesel trucks,’.

According to Rolf Dobereiner, product line manager at AVL List. This increased requirement consumes up to 40 kilowatts, reducing driving performance and creating challenges for achieving the high-power outputs needed for heavy-duty haulage.

An unexpected dark horse has emerged: the hydrogen combustion engine. This technology offers compelling benefits, as it doesn't require the costly, high-purity hydrogen needed for fuel cells.

Christian Barba, Senior Manager at Daimler Truck, noted that it saves costs ‘as 80 percent of the parts of a diesel engine can be reused.’

Moreover, Anton Arnberger, Senior Product Manager at AVL List, reported that it ‘is the only zero-emission technology that does not require the use of rare earths.’

The hydrogen engine ‘could achieve the torque and power of a gas or diesel engine,’ said Lei Liu, a manager at Cummins in Beijing. Cummins is testing these vehicles in India, where they are seen as a main pillar for transport decarbonisation, given the lack of a comprehensive power grid required for electric trucks.

Developers are also looking at alternatives to gaseous hydrogen. The trend in Europe is moving towards liquid hydrogen, which allows for longer ranges and is cheaper to store.

Furthermore, Yuan Shen, Chief Developer at Zhejiang Geely Holding in China, proposed methanol as ‘the best carrier of hydrogen,’ as it is a liquid fuel that is easy and safer to store and transport.

Shipping, special vehicles and hybridisation

Decarbonisation is equally challenging on the high seas. Andreas Wimmer, a professor at Graz University of Technology, reported that engines for the 100,000 ocean-going vessels in service today have a life span of over 25 years and cost hundreds of millions of euros.

By 2050, these giants must also be CO2-free. While the combustion engine will remain, fossil heavy fuel oil must be replaced by ammonia (considered an ‘up-and-comer’), methanol or limited-quantity biofuel.

The special vehicle sector – such as construction and agricultural machinery – presents one of the toughest challenges. Stefan Loser, department head at MAN Truck & Bus, noted that a forage harvester would need ‘36 tonnes of batteries to run purely on electricity,’ which is impractical. For such machines, which are used intensively for short periods, hydrogen fuel cells or combustion engines running on synthetic fuels will be essential.

Finally, in the USA, where the decarbonisation of transport is ‘less aggressive than in Europe,’ according to Chris Bitsis, head of development at the Southwest Research Institute, hybridisation (the combination of combustion engines and electric drives) is seen as a key strategy to maintain everyday usability while significantly reducing consumption and emissions.

Summing up the current situation, Prof. Bernhard Geringer concluded that battery-electric drives in commercial vehicles are currently only realistic for distances of up to 500 km and with sufficient fast-charging options. He stressed that the special vehicle sector is particularly difficult, which is where ‘hydrogen fuel cell drives or combustion engines with synthetic fuels come into play.’

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Pre-owned car marketplace Cars24 has announced the launch of AI Labs, a dedicated initiative designed to develop artificial intelligence-native products and support early-stage entrepreneurs.

As part of the program, the company has committed a USD 20 million investment fund targeted at startups and development teams building transformative AI technologies.

The move marks an expansion of Cars24’s internal technology strategy, where machine learning and artificial intelligence models have already been integrated into core business operations to manage decision-making workflows and customer experience interfaces. Through AI Labs, the company will extend its technical resources externally to independent software engineers and startup founders.

To establish the infrastructure for the program, Cars24 has partnered with technology providers including OpenAI, Amazon Web Services (AWS) and ElevenLabs. This ecosystem will provide participating developers with cloud infrastructure, technical expertise, distribution networks and advanced language and voice synthesis models to accelerate product deployment.

The operational focus of AI Labs is divided into three primary activities:

• Build: Developing proprietary AI-native applications and contributing to global open-source software innovation.
• Partner: Collaborating with established artificial intelligence firms to encourage industry experimentation and technology adoption.
• Invest: Supplying seed capital and strategic support to early-stage businesses building software categories.

Beyond direct equity investments, the initiative will fund community engagement programs, including regional hackathons, builder incubation programs and collaborative open-source projects designed to stimulate developer experimentation.

Vikram Chopra, Founder and CEO, Cars24, said, “Every major technology shift creates a handful of companies that go on to define the future. We believe AI is the biggest shift of our generation, and the opportunity ahead is far larger than anything we've seen before. Over the last few years, we've seen AI fundamentally change how we operate, build products, and serve customers AI Labs is our way of giving back to the ecosystem that is shaping this future. We want to back founders early, help them move faster and support the people building things that seem impossible today but inevitable tomorrow.”

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Automotive supplier Valeo and Electronic Design Automation software provider Zuken have announced a strategic partnership to develop an open, artificial intelligence-assisted electronic design platform. The collaboration will operate under a joint program named the ‘Zuken Valeo InnoLab’.

The initiative integrates Zuken's AI architecture with Valeo’s custom AI agents and industrial data to create a real-time collaborative ecosystem between software tools and engineers. The primary objective of the program is to reduce hardware design timelines while maintaining structural robustness across complex automotive electronic systems.

The technical development framework spans the entire electronic design flow and is organised into four main operational areas:

• Functional Generative Design: Valeo will deploy its generative AI models within Zuken’s System Planner software to instantly generate and evaluate multi-criteria system architectures based on predefined corporate standards.
• Digital Continuity: Zuken’s open architecture will interface with Valeo’s existing digital ecosystem to provide end-to-end data traceability. This integration is designed to comply with the Automotive SPICE 4.0 (ASPICE4.0) Hardware Engineering process group standard, allowing Valeo's AI to process data and execute automated actions directly within the platform.
• Assisted Detailed Design: Valeo will integrate virtual AI copilot agents to assist engineering teams in real time with hardware rule verification, solution searching, and constraint implementations. Concurrently, Zuken is developing native AI functions to accelerate schematic entries by drawing from Valeo’s standardised components database.
• Automated Placement and Routing: Physical circuit integration will utilise Zuken’s Design Force engine, which features automated placement and routing algorithms. Valeo will use Zuken's software development kit to train the AI engine against specific automotive environmental and physical constraints to achieve correct initial executions.

Christophe Le Ligne, Vice-President – Research and Development, Valeo, said, “For Valeo, Zuken is much more than a software provider; it is a true innovation partner. The power of Zuken’s AI roadmap, combined with the exceptional openness of its architecture, allows us to hybridise our own artificial intelligence tools with their engine. This win-win partnership is the best way to tackle the challenge of automotive complexity by slashing our design times while guaranteeing 100% robustness.”

Ryosuke Takagi, Executive Officer and General Manager – R&D Division, Zuken, added, “Our vision at Zuken has always been to provide intelligent tools that adapt to our customers’ most complex challenges. Collaborating with a technological leader like Valeo pushes our ‘Autonomous Brain’ roadmap to its highest level of performance. By opening our System Planner, Design Gateway, and Design Force solutions to Valeo’s AI agents, we demonstrate that the true power of AI in engineering lies in the alliance between a high-performance software engine and expert industrial know-how.”

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Artificial intelligence software developer Helm.ai has launched two foundation models, GenSim-3 and VidGen-3, establishing a native Full HD (1920x1080) resolution standard for generative simulation across a 6-camera, 360-degree surround-view suite.

The architecture delivers 5x the pixel density of industry benchmarks to assist automotive developers facing the limitation where physical collection of edge cases becomes logistically restrictive.

Traditional generative world models typically cap resolution at roughly 0.4 megapixels per camera. Helm.ai’s platform outputs a native 2 megapixels per camera, yielding a synchronised 12-megapixel synthetic canvas per timestep. This specification matches the hardware parameters of production-grade vehicle cameras to reduce the domain gap for SAE Level 2 through Level 4 autonomous vehicle development.

The platform functions as a virtual sensor twin by mathematically replicating physical constraints and hardware anomalies, including lens flares, sensor banding patterns, and exposure blinding. To accommodate different neural network training routines, the pipeline can be configured to a high-speed validation mode using a three-camera setup at 30 frames per second, or a spatial context mode generating a six-camera surround view at 5 frames per second.

Data generation is split into two operational pipelines. GenSim-3 focuses on data augmentation by modifying environmental parameters such as weather, lighting, and object surfaces across real-world video segments at native 2MP resolution. VidGen-3 focuses on data creation, synthesising driving sequences from scratch by simulating environments, agent behaviours, and traffic logic without baseline video to patch geographic data gaps.

Helm.ai achieved the 2MP standard using a cluster of a few hundred GPUs rather than the thousands typically required for sub-HD video generation. This framework reduces the GPU infrastructure footprint for vehicle manufacturers and provides a method for compressing autonomous driving software onto mass-market on-vehicle compute chips.

Vladislav Voroninski, CEO and Founder, Helm.ai, said, "We are moving the industry from standard 'AI video' to authentic, hardware-accurate sensor emulation. By leading with a Full HD (2MP) standard and a 12-megapixel total aggregate capability per timestep, we have solved the resolution bottleneck that has historically limited the utility of generative AI in safety-critical systems. By optimising our compute architecture, we are giving our partners a high-performance platform to validate their autonomous stacks using synthetic data that perfectly matches the fidelity of their actual production sensors."

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Global automotive technology supplier Marelli has marked the 30th anniversary of its flagship electronics manufacturing plant in Guangzhou. Established in 1996 as Marelli’s inaugural manufacturing investment in China, the facility has transformed from a baseline assembly outpost into a major smart manufacturing and hardware-software validation centre.

Over the past three decades, the facility has expanded from a single operational production line with approximately 100 technicians into a 30,000-square-meter automotive electronics campus.

Today, the facility employs nearly 1,000 people and runs 66 active production lines, manufacturing components for both localised Chinese vehicle programs and global vehicle architectures.

The campus houses an adjacent, fully integrated Engineering Center that holds more than 100 registered patents. The manufacturing framework integrates high-precision assembly lines, automated optical bonding modules and site-wide rooftop solar arrays designed to manage factory energy overheads and lower operational carbon density.

The Guangzhou plant functions as a strategic industrialisation hub focused on low-cost, scalable architectures suited for the industry transition toward connected, software-defined vehicles (SDVs). The facility specialises in several high-growth hardware and display segments like advanced display solutions based on Mini-LED and MicroLED technologies. Additional key platforms include electronic control units (ECUs) for body and seat systems, zone control units, as well as digital cockpits, digital instrument clusters, and 5G telematics systems.

Ravi Tallapragada, President of Marelli’s Electronics business unit, said, “Our Guangzhou plant is a cornerstone of Marelli’s Electronics business in China and a powerful example of how innovation and advanced manufacturing can drive sustainable growth. Over the past 30 years, the team has continuously evolved its capabilities, developing advanced technologies and scalable platforms that address the rapid transformation of the automotive industry, building on long-standing collaboration with customers and partners. I’m proud of our team in Guangzhou and confident that the plant will continue to play a key role in shaping Marelli’s future globally.”

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