Source: Bike Europe

The LEVA-EU member has become globally renowned for its advanced, lightweight e-bike systems, offering a range of solutions for brands, from rear hub drives for gravel, road and urban bikes to a full power mid-drive platform. Bike Europe covers how its “Light.Sport.Smart” philosophy ensures high integration, weight optimisation and intelligent control for improved performance.

As part of MAHLE group, a global technology leader in automotive components, MAHLE SmartBike Systems accesses high-quality resources of electronics, lightweight construction, power electronics and validation protocols, facilitating it to produce highly reliable, scalable and consistent quality for the e-bike industry.

Its motto of “Light.Sport.Smart” is at the forefront of its development for both hub and mid drive platforms, to make sure that performance improvements align with integration and weight optimisation, as well as intelligent system control, with its clearly defined offering that’s targeted for specific rider groups and OEM strategies.

Rear hubs

Efficiency and a natural riding feel are the biggest priorities for the X Series, to provide smooth and consistent assistance across both low and high cadences.

Its X Series hub drives, such as the X20, X30, X35 and XS, are innovated for road, gravel and urban riding scenarios that require discretion, light systems that can be seamlessly integrated into various frame designs.

In this range, the weight of its motors range from approximately 1.4 kg for the X20 and ends at around 1.9 kg for the X30, due to each system being tailored for different bike concepts and usage targets.

How its sensing and tuning differentiates riding experiences

A key part of MAHLE’s offering is that brands can select their preferred ride characteristics. For example, depending on chosen system and OEM preferences, an X Series build can adopt torque-based sensing or PAS configurations based on cadence, enabling how assistance can respond to rider input.

MAHLE supports tuning at production level, giving flexibility for OEMs to modify support curves, responsiveness and a general “feel” for aligning with their desired model positioning. It’s noted that from one brand to another, behaviour can vary majorly when using similar hardware.

Through the years, hundreds of models have been powered by the X Series, including Bianchi, Cannondale, Orbea and Merida.

The X ecosystem

Besides the X motors, there is the eX1 external battery, Trio Remote, Pulsar One display, Energy Hub charger and Gateway, providing a range of control, display, charging and range extension options for daily use and longer rides.

For OEM partners, the option of portfolio expansion is simplified with all components being compatible across MAHLE’s X and M platforms with continuous firmware updates for optimised integration and performance through time.

M40 full power mid-drive system and its multi-sensor control system

MAHLE maintained its core integration philosophy in developing this system for electric mountain bikes. It is positioned as one of the lightest solutions in the full power segment while ensuring high performance.

The M40 brings a torque of up to 105 Nm and a peak power of 850 W, alongside an assistance ratio of up to 600%.

Its 48V system architecture boasts a motor unit weighing 2.5 kg, that comes close to 5 kg alongside the installation of the lightweight iM5 battery (534Wh). The option of a heavier iM8 (800 Wh) is also available, to give extended range for applications that are more challenging.

A core feature of the M40 is its multi sensor control system, which delivers precise and responsive motor control, thanks to its high-resolution wheel speed sensor (bringing 84 pulses per revolution), integrated torque sensor within the motor axle, working alongside gyroscope and accelerometer inputs.

The sensor supports features including:

• Auto Hold, which prevents rollback on steep inclines
• Dynamic Overrun, which extends assistance momentarily after pedalling to keep flow and control

Just like the X Series, bike brands can define the assistance behaviour, with production level tuning allowing them to configure their preferred support curves and responsiveness, enabling them to differentiate their model positioning across their line-up.

MAHLE’s key design principles across its solutions

From its hub drives to the M40 mid drive, MAHLE SmartBike Systems provides a whole platform approach for OEMs, with an ecosystem built for scaling across various segments. It prioritises integration first with a light-weight system and software-led control for natural, intuitive riding experiences.

MAHLE SmartBike Systems customer support updates

The company has announced an update to its Customer Service contact details, requesting that customers, partners and dealers use official contact forms on its website and Dealer Portal.

This update is already activated for the DACH region, and will activate for France and the Benelux region on 10th April, with Italy, Iberia and the Rest of the World on 24th April.

MAHLE SmartBike Systems distribution and technical partner updates in Denmark and Australia

To make MAHLE accessories and spare parts more accessible for its dealers in Denmark, it has announced a partnership with Sport Import GmbH.

Furthermore, the company has announced an update for its Australian distributor and technical service structure, with De Grandi Cycle Works operating as its official distributor and Service Partner since 23 March 2026.