LEVA-EU member MAHLE SmartBike Systems’ Director of Strategy and Business Development, Marco A. de la Serna, was interviewed by Spanish media Diario Palentino about how the company is improving the city of Palencia with various initiatives.
MAHLE SmartBike Systems’ operation and R&D centre is situated in the Spanish city, where it develops lightweight and efficient micromobility solutions to scale globally. From this work, the centre creates processes to reduce environmental impact, encourage regular bicycle use, as well as generate a skilled workforce for the region.
On a wider business and educational scale, the brand has spoken of strengthening of its partnerships with local universities (Salamanca and Valladolid) and institutes, enabling local talent to be employed by its team. Furthermore, it is working on establishing the Cycling Roundtable for Castilla y León, a project which aims to bring administrations, businesses and cycling groups to progress regulations, standardisation and awareness initiatives in the Spanish region.
With these developments, MAHLE states its intention of making Palencia a benchmark for sustainable urban mobility with local employment and investment opportunities, by inviting administrations, citizens and companies to collaborate with them.
The Diario Palentino interview marks another highlight of a successful year for MAHLE Smart Bike Systems, with key achievements including:
Sants has launched its latest electric mountain bike range with the LEVA-EU member’s MAHLE M40 System, delivering 105 Nm of torque in a compact and lightweight design, integrating an 800 Wh battery, elevating these models to bring high precision, control, and endurance across challenging terrain.
The system’s smooth, adaptive assistance responds intuitively to each rider’s pedalling style, while Sants’ carefully designed geometry and component selection ensure agile handling and long-term reliability. Riders can further customise assist levels and access real-time ride data through MAHLE’s My Smartbike app, enhancing both connectivity and efficiency.
At the forefront of the new Sants range is the Sants E SF 4.0, which combines advanced engineering with intelligent pedal assistance for riders seeking control and performance on every trail. The MAHLE M40 System incorporates a high-resolution speed sensor capable of detecting changes within less than 3 cm, alongside torque and cadence sensors for near-instant response to every pedal stroke. Its dynamic control logic fine-tunes power output in real time to provide smooth and natural assistance that’s tailored to the rider’s style.
Sants’ new eMTB range promises a blend of precision, power, and endurance that is engineered for the wild and powered by MAHLE.
A video showcasing its powerful performance can be accessed on MAHLE Smart Bike Systems’ LinkedIn page.
The LEVA-EU member has officially launched its Smart Training program for dealers, with sessions that are already underway and several locations nearing full capacity.
The training sessions, taking place in multiple locations across Europe and the UK, are designed for shops working with MAHLE e-bike systems to provide them with in-depth, practical insights into the X Series and M Series. Attendees will have the opportunity to gain the knowledge and skills necessary for enhancing service quality and improving the overall customer experience.
Once they have completed the program, attendees will be recognized as Certified Partner PROs, unlocking exclusive benefits and reinforcing their expertise through advanced technical training.
Dealers are encouraged to register promptly to secure a spot in upcoming sessions and take advantage of this opportunity to strengthen their capabilities in servicing MAHLE products.
The registration link for MAHLE Smart Training sessions can be accessed here.
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X20 System upgrades for a more responsive and versatile riding experience
65 Newton metres (Nm) of torque, 275 watts (W) of peak power, 1.4 kilograms (kg) light
Now compatible with Universal Derailleur Hanger (UDH)
Driven by a commitment to continuous innovation, MAHLE SmartBike Systems has enhanced the performance of its flagship X20 rear hub system. The new X20 increases torque to 65 Nm (up 18%) and boosts peak power output to 275 W (up 10%), delivering sharper acceleration, improved climbing capability, and a more responsive ride — all while maintaining the system’s ultra-light 1.4 kg design. In addition to the performance improvements, the latest hardware generation of the X20 now features compatibility with the Universal Derailleur Hanger (UDH) standard. This advancement allows manufacturers to integrate more robust derailleur systems, which improve shifting precision, offer better protection against impact, and require less maintenance. Riders who already own an X20 bike will progressively gain access to the increased torque and power through firmware updates released by MAHLE throughout 2025.
“This upgrade is about giving riders more choice in how they ride — whether they want more support on climbs, a more dynamic feel on flat terrains, or simply a smoother experience overall. We’ve engineered a solution that delivers enhanced performance without adding weight or complexity. It’s an evolution of the X20 System — staying true to our ‘Light. Sport. Smart.’ philosophy,” said Jochen Sommer, Head of MAHLE SmartBike Systems.
The new X20 System can already be experienced across a wide range of bike models from MAHLE’s extensive list of brand partners — taking lightweight e-performance to new heights across road, gravel, and urban segments.
MAHLE SmartBike Systems will shortly be exhibiting its latest innovations at IAA Mobility on 9-14 September, then at Taichung Bike Week from 16-19 September.
The company MAHLE SmartBike Systems is the specialist division for the design and development of drive systems for eBikes as part of the German MAHLE group, an international leader in sustainable mobility solutions for both present and future.
The more than 150-person-strong team is made up of software and hardware engineers, industrial and electronic engineers, quality specialists, 3D designers, creatives, production and materials experts, and a long list of professionals in addition to a further 80 people across the group’s different centers in Spain, Germany, and Asia.
With the headquarters of this major project located in Palencia, MAHLE SmartBike Systems brings together MAHLE’s R&D, Marketing, Operations and Sales activities within the eBike sector.
The ultralight and compact MAHLE systems are comprised of the motor, batteries, controllers, components, and all types of intelligent solutions for eBikes and are integrated and perfectly interconnected with each other in order to offer cyclists a completely personalized experience. Thanks to all these characteristics, more than 70 brands around the world, including those that as a result of their innovation are revolutionizing the cycling industry, incorporate MAHLE drive systems as the perfect choice in terms of integration, cost, and efficiency for electric mobility.
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About MAHLE
MAHLE is a leading international development partner and supplier to the automotive industry with customers in both passenger car and commercial vehicle sectors. Founded in 1920, the technology group is working on the climate-neutral mobility of tomorrow, with a focus on the strategic areas of e-mobility and thermal management as well as further technology fields to reduce carbon emissions, such as fuel cells or highly efficient, clean combustion engines that also run on synthetic fuels or hydrogen. Today, one in every two vehicles globally is equipped with MAHLE components.
MAHLE generated sales of €11.7 billion in 2024. The company has almost 68,000 employees at 135 production locations and 11 technology centers in 28 countries. (as at: 12/31/2024)
LEVA-EU member MAHLE has announced new plans to invest millions into its e-bike sector after it was reported as being highly successful in its 2024 financial overview.
MAHLE SmartBike Systems will invest millions more to innovate solutions in improving e-bike efficiency and performance, with its CEO Arnd Franz stating that “the e-bike sector was their standout success, supplying more than 60 e-bike brands across all segments.”
Although MAHLE originates in the automotive industry, which is experiencing regulatory obstacles and market uncertainty, the company is looking to work on new non-automotive applications, such as e-bikes, where MAHLE’s subsidiary, SmartBike System, entered the market successfully.
Investment plans to triple R&D capacity
The R&D centre of MAHLE SmartBike Systems is based in Palencia, Spain. Its director of strategy and business development, Marco Antonio de la Serna, said the following in a recent interview: “We invest significantly in e-bike development to maintain a leading position in the market and offer cutting-edge products to our customers.”
MAHLE currently invests between €10-12 million into R&D each year at its headquarters which employs approximately 150 professionals that are mostly mechanical, electrical and computer engineers. To increase MAHLE’s work for the e-bike sector, its R&D centre will receive an additional investment of €4 million to triple the design and marketing of its e-bike drive systems.
Additional MAHLE H1 developments
This announcement is the latest news to come out of MAHLE in its efforts to improve global sustainable mobility, following the launch of its first full power mid-drive and the one year anniversary of its global biomobility center in Brazil.
M40 is one of the most powerful systems on the market
Newly developed batteries, controller and display complement the M40 drive system
Full compatibility with MAHLE ecosystem
With M40, MAHLE SmartBike Systems is launching the new M series, which will be expanded in the coming years
M40 is now available
MAHLE SmartBike Systems, which has been extremely successful for years with hub drives as part of lightweight integrated and smart eBike systems, is now expanding its range to include a mid-drive for the first time, thereby entering the e-mountain bike (eMTB) segment. The new M40 full-power drive system offers full control, power and high efficiency even in demanding environments and even at high support levels and cadences. The M40 weighs just 2.5 kilograms and generates an impressive torque of 105 Newton metres (Nm) and a peak power of 850 watts (W). This makes the M40 one of the most powerful systems on the market. Newly developed batteries, controller, display and other accessories complement the M40 drive system, which is also fully compatible with all accessories and digital tools of the established MAHLE ecosystem. The M40 is the first drive system in the new M series from MAHLE Smartbike Systems, which will be further expanded in the coming years to complement the existing X series with the X20, X30 and XS hub drives. The M40 drive system is available immediately.
From road pioneer to trail expert
“Thanks to state-of-the-art technologies, precision engineering and intelligent connectivity, the M40 sets new standards in the category of full-power mid- motors,” said Jochen Sommer, Managing Director of MAHLE SmartBike Systems. “With the M40 system, MAHLE SmartBike Systems is reaffirming its claim to continue driving the development of the eBike industry in the mountain bike segment.”
The M40 was developed especially for electrified mountain bikes and trekking bikes. It offers off-road e-bikers a powerful but natural riding experience with active yet controlled support that adapts to every riding situation. Thanks to its strengths, M40 is also a very well-balanced system for urban use and can therefore be used in a variety of ways.
Performance data of the motor
True to the “Light. Sport. Smart.” philosophy of MAHLE Smartbike Systems, this new drive system is also extremely compact. The centrepiece is the ultra-modern drive unit, which is housed in an ultra-light magnesium casing. With a weight of just 2.5 kg, a torque of 105 Nm and a peak power of 850 W, the M40 has one of the best power-to-weight ratios on the market: 340 W/kg. In addition, the drive delivers a support ratio of up to 400 per cent.
In conjunction with an optimised aluminium shaft and a Q-factor of 179 mm, the motor offers exceptional versatility combined with top performance.
The drive system is compatible with the ETOR crank standard and therefore ensures simple integration into a wide range of cranksets available on the market. The motor is decoupled from the frame via the MAHLE Decoupling Mounting System (DMS) in order to reduce the transmission of vibrations into the frame.
System control and behaviour
The M40 system offers a powerful yet natural riding experience with strong controlled support that adapts seamlessly to every riding situation. It ensures smooth power delivery even at high cadence and enables rider-controlled performance, especially on technical trails and when climbing. Equipped with the most advanced sensors on the market, the M40 offers maximum responsiveness. The integrated software uses an ultra-precise speed sensor to ensure a smooth, progressive motor response without jerky movements or abrupt power peaks. The system collects riding data and adjusts the assistance dynamically and precisely. With the ability to recognise changes in speed over a distance of less than three centimetres, the system offers greater accuracy than comparable offerings on the market.
The M40 system also includes advanced driving control functions:
Motor Dynamic Overrun: reduces the braking effect of the motor and enables a smooth overrun after pedalling. This makes it easy to overcome obstacles. In addition, thanks to a highly sensitive sensor, the system adapts independently to the riding speed and ensures a more natural riding experience that is customised to the riding requirements.
Hill Brake: prevents rolling back when stopping on steep inclines thanks to the engine’s “Auto Hold” function for a controlled safe start.
Batteries, range and efficiency
An outstanding feature of the M40 drive is its optimised energy consumption, particularly at high support levels. This enables the use of smaller, lighter batteries without any loss of performance and offers manufacturers more design freedom for agile and easy-to-handle bikes.
The M40 is powered by the new, powerful 48V batteries from MAHLE, which are developed and manufactured in Europe.
iM5 Battery (534 watt hours – Wh): Together with the iM5 battery, the M40 drive unit weighs close to 5 kg, making it one of the lightest combinations on the market.
iM8 Battery (800 Wh): allows a range of up to 150 km autonomy or 2,500 m altitude.
As both batteries are identical in shape and have the same connections, they can be used and exchanged as required. They are also fast-charging.
Individualisation
MAHLE SmartBike Systems develops eBike solutions that every bicycle manufacturer can customise and configure to suit their brand identity and application. This also applies to the M40 system. The motor settings are defined together with the manufacturer and saved at the end of a bike’s production process. This means that every brand that uses the M40 system can offer bikes with unique riding characteristics. Certain components from other manufacturers can also be integrated into the MAHLE ecosystem via the MAHLE Gateway.
Accessories
MAHLE presents new accessories with the M40 system:
Head Unit+: is a compact and modern display with a 1.9″ colour screen and multiple mounting options. It offers clear and customisable information at a glance. The Head Unit+ is updateable and can be expanded with future functionalities and improvements.
Trio Remote: is a wireless, compact control unit that is easy to use and provides intuitive access to the most important functions and LED status displays while the rider keeps their hands securely on the handlebars with the possibility of change the levels of assistance. A second Trio unit can be added with shortcuts to control additional functions.
Existing MAHLE accessories such as Duo remote, eShifters or the ANT+ bike computer Pulsar One can also be used for M40 with full compatibility.
Connectivity
In addition, users can connect to the digital ecosystem of MAHLE Smartbike Systems via their eBike, laptop, smartphone or Apple Watch and access its numerous functionalities.
LEVA-EU member MAHLE has released a redesigned version of its SmartBike Lab app, aimed at improving functionality and usability for its users. The update is the result of direct input from dealers, with a focus on streamlining diagnostics and repair workflows.
The MAHLE SmartBike Lab app is a specialized mobile application developed by MAHLE SmartBike Systems, that has been created primarily for e-bike dealers and service technicians. The application serves as a comprehensive tool for diagnosing, configuring, and maintaining e-bikes equipped with MAHLE systems, such as the X20, X30, X35, and XS platforms
Its latest enhancements include:
A modernised interface featuring a refined colour palette and clearer icons for diagnostics, device installation, and component updates.
Simplified navigation, allowing users to access diagnosis tools, repair guidance, and engineering mode within just two taps.
Branding updates that bring the app in line with the broader MAHLE SmartBike identity.
Enhanced readability designed for use in workshop lighting environments.
These improvements are designed to make technical checks and firmware updates quicker and more efficient, ultimately helping service teams return bikes to riders faster. The updated SmartBike Lab app is now available on the Apple Store and Google Play.
LEVA-EU member MAHLE SmartBike Systems has confirmed plans to renew its collaboration with Team Sara Assicurazioni and Orbea for the Italian e-mobility event, taking place across the country from 10 May to 1 June 2025.
Giro-E ENEL, organised by RCS Sport, is a cycling event where e-bike riding enthusiasts exclusively participate on the same route as the prestigious Giro d’Italia racing event of approximately 1,091 km. Participants in the Giro-E ride most stages together, apart from a few stages where teams will take on regularity and special tests, as well as a sprint race in the final part of the event.
Revisiting a winning partnership
MAHLE’s partnership with Orbea and Team Sara Assicurazioni proved very successful in 2024 with the team proving victorious in last years race. For the 2025 edition, they will aim to defend this title, with Orbea’s Gain e-bikes being powered by the MAHLE X20 System.
MAHLE Strava competition
MAHLE is also inviting e-bike riders from 12 May until 1 June to join its very own Strava e-bike challenge that mirrors the Giro-E challenge, with the top 10 riders being in with the chance to win a MAHLE × GOBIK Maillot. More information about the exclusive competition can be found on the MAHLE website.
LEVA-EU member MAHLE Smartbike Systems has introduced their new product Gateway, a compact interface that opens the door to broader compatibility across the eBike ecosystem, empowering manufacturers to create more connected, efficient eBikes.
This innovative interface converts battery voltage to power additional components while implementing the CAN protocol for integrated communication. The system features voltage conversion, CAN communication, a compact design weighing just 142 grams, and easy integration capabilities with installation inside the top tube.
The first Gateway integration powers Pinion SmartShift directly from the eBike battery, eliminating the need for a dedicated battery and reducing weight. This ensures continuous operation and simplifies the integration process, paving the way for smarter, more versatile eBikes.
You can find out more details about the MAHLE Gateway in the video below.
Leading brands such as Schindelhauer Bikes, Nørdic Bikes, Konrad Bikes, and URWAHN Bikes will soon offer models featuring Gateway, setting a new standard for eBike connectivity and efficiency.
