Tier 1 suppliers Valeo has announced that based on the successful joint development with a European OEM on the magnet-free electric motor technology (EESM – Externally Excited Synchronous Motor), it is now extending its portfolio of magnet-free electric motors towards upper segment vehicles together with component major Mahle.

The partners have joined forces to develop an innovative magnet-free electric axle system, targeting upper segment electric vehicles with peak power ranging from 220 kW to 350 kW.

The iBEE system (inner Brushless Electrical Excitation), is a cutting-edge technology that aims to revolutionise performance and efficiency of magnet-free electric motors. Valeo and Mahle signed a Joint Development Agreement to combine both Valeo’s expertise in electric motors, highly efficient inverters and associated motor control laws and the expertise of Mahle on magnet-free rotor with its Mahle Contactless Transmitter (MCT) technology.

They are working on an innovative cooling concept in order to achieve an outstanding continuous to peak power ratio. Moreover, the carbon footprint is expected to be reduced by more than 40 percent versus a permanent magnet electric motor of equivalent power. The testing of the first prototypes will be completed by the end of 2024.

Xavier Dupont, Valeo Power Division CEO said, “This cooperation with Mahle is a perfect match. Mahle develops the EESM rotor and their brushless excitation system. Based on our power electronics know-how, Valeo provides a dedicated control of this electric motor and brushless system embedded in our inverter. This partnership allows Valeo to complete its EESM portfolio towards upper segment and is key to support the evolution of the automotive industry towards more innovative sustainable solutions.''

Martin Wellhoeffer, Member of the Mahle Group Management Board said, “In this project two front runners of electrification are joining forces. The new e-axle will benefit from Mahle’s expertise in contactless transmitter technology. Together we will be setting a new benchmark in packaging and efficiency for EESM based e-axles and taking the next step for our customers towards future mobility.”

Valeo's first EESM development is based on cooperation with a European OEM launched in 2022 in order to create a new magnet-free electric motor generation (EESM). The initial targets of the project were double; first to get an all-in-one architecture with a new stator and cooling technology in order to increase by 30 percent the power density compared to the current motors equipping the current OEM’s vehicles on the road. Secondly, to shrink its carbon footprint by 30 percent versus an electric motor equipped with magnets (PMSM). A validation phase for more than 6 months was successfully ended with results level over the initial expectations in terms of power and efficiency especially thanks to Valeo inverter expertise.

The performances match the level of permanent magnet electric motors for B/C segment vehicles with all benefits of a magnet-free technology (no rare earth and lower carbon footprint)

As part of its electrification strategy Mahle has been focusing on developing electric drive systems. Its contactless transmitter technology for magnet-free electric motors is testament to the company’s strong expertise in this field. Thanks to its high maturity level it is a key enabler for the next evolution of EESM-based e-axles.

Avoiding the use of rare earth materials does not only positively contribute to the sustainability of e-mobility, but is also advantageous in terms of costs and resource security. The key feature is the inductive and thus contactless and wear-free power transmission allowing motor operation at benchmark efficiency level.

Automotive component supplier Sundram Fasteners has announced its financial results for the quarter and year ended 31 March 2025.

For Q4 FY2025, the revenue came at INR 13.53 billion, up from INR 12.78 billion in the same period last year. Domestic sales stood at INR 9 billion (INR 8.4 billion in Q4 FY2024), while exports were INR 4 billion (INR 3 billion in Q4 FY2024). Net profit came at INR 1.34 billion as compared to INR 1.32 billion.

For FY2025, total revenue was INR 52 billion, as against INR 49 billion, which includes domestic sales of INR 34 billion, as against INR 33 billion last year. Exports grew by 12.39 percent to INR 15 billion, as against INR 14 billion last year. The net profit came at INR 5 billion, as against INR 4 billion last year.

The consolidated revenue for FY2025 came at INR 59.83 billion, as against INR 57.2 billion last year, while net profit came at INR 5.4 billion, compared to INR 5.25 billion last year.

Arathi Krishna, Managing Director, Sundram Fasteners, said, “We achieved the highest-ever quarterly PAT at INR 1.34 billion by maintaining strong financial discipline, sustaining a positive cash balance and adopting best practices in quality management and automation. This growth is particularly encouraging as we have witnessed significant progress in our non-auto business, which has contributed to our overall robust performance. Our growth is supported by strong domestic and export order book. We remain committed to driving volume-led growth by leveraging emerging opportunities in the electric vehicle segment and continuing our focus on innovation which will enable us to outpace industry growth rates.”

During the year, Sundram Fasteners incurred a CAPEX of INR 3.7 billion towards capacity expansion and new projects across internal combustion engine vehicles (ICE), plug-in hybrids and electric vehicles.

Tier 1 supplier UNO Minda has got approval from its Board to set up a new greenfield plant for manufacturing of high-voltage electric powertrain for the passenger vehicle and commercial vehicles segment. These products include combined charging units, e-axles, inverters, and motors. The location still being determined is expected to see an investment of around INR 4.23 billion, which will be funded through a combination of debt and equity.

UNO Minda Auto Innovations, a subsidiary of the company, will execute the project, which subsequently will be converted into a joint venture company with Suzhou Inovance Automotive (Inovance Automotive).

The JV eventually will see Uno Minda hold 70 percent equity stake. The CAPEX will be phased over the next three years, with Phase 1 expected to be commissioned by Q2 FY2027.

Ravi Mehra, Managing Director, UNO Minda Group, said; “This investment underscores Uno Minda's commitment to driving the future of electric mobility in India. By establishing this state-of-the-art facility, we will be well-positioned to meet the growing demand for high-voltage EV powertrain solutions. Our partnership with Inovance Automotive brings together our respective strengths and will enable us to deliver cutting-edge technology to our customers.”

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."

Uno Minda, a tier 1 automotive supplier to OEMs, has introduced projector headlights for seven-seater MPVs in the Indian aftermarket.

The new headlights are designed to improve visibility and meet safety needs during night driving and adverse weather. They feature a hard-coated lens to prevent yellowing and damage and include Japanese optics with an integrated projector for better beam focus.

Anand Kumar, Head of Product & Strategy – Aftermarket, Uno Minda, said, “At Uno Minda, we believe that style and safety should go hand in hand. Our newly launched headlights for 7-seater cars are designed to enhance both visibility and aesthetics, ensuring a superior driving experience. The bright and advanced headlights, featuring Japanese optics technology with an integrated projector, deliver a superior beam pattern for enhanced visibility and a well-illuminated driving experience. Engineered for safety, they ensure optimal performance during nighttime and adverse weather conditions. These headlights come with a 100 percent coated lens that provides a shatterproof surface, preventing discoloration and maintaining long-term clarity. The rust-free silicon-coated reflectors ensure extended durability while sustaining optimal light output.”

The headlights are priced at INR 5,200, come with a one-year warranty, and is available across online and e-commerce platforms in India.