MAHLE has secured its first series order for an advanced high-performance cooling module designed for megawatt charging systems (MCS), marking a significant milestone in fast-charging infrastructure for electric commercial vehicles.
The order comes from a leading European cable manufacturer and outfitter of MCS charging stations, which cited performance efficiency and cost-effectiveness as decisive factors in selecting MAHLE’s solution.
“With this innovative cooling module, MAHLE is expanding its product portfolio for intelligent charging solutions and setting new standards in electric truck and heavy-duty vehicle infrastructure,” said Christian Kuechlin, Vice President of MAHLE Industrial Thermal Systems.
Megawatt charging systems, primarily deployed at motorway service stations and logistics hubs, are capable of delivering up to 3.75 MW per charging station. However, they generate waste heat of up to 8 kW, necessitating advanced thermal management to ensure peak performance.
MAHLE’s modular cooling module employs up to four heat exchangers in series, using air-cooling mechanisms to efficiently dissipate heat. “Our system draws in air and uses fans to transport waste heat outside, ensuring continuous high-speed charging without overheating,” explained Norman Nagel, Head of Business Development at MAHLE Industrial Thermal Systems.
Versatile, Scalable Cooling Technology
The adaptable design of the cooling module makes it suitable not only for commercial vehicle charging stations but also for passenger cars, light commercial vehicles, maritime applications, and rail systems.
- Extreme Temperature Resilience: Engineered to function seamlessly in ambient temperatures ranging from -35°C to +50°C without performance loss.
- High-Speed Charging Capability: Supports up to 500 kW fast charging for electric passenger vehicles and light commercial fleets.
- Customisable and Modular: The system’s design allows for flexible integration into different charging station configurations based on customer requirements.
As part of its broader electrification strategy, MAHLE continues to push technological advancements in electric drives, intelligent charging solutions, and thermal management—all critical for the next generation of sustainable mobility.
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