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 been awarded the prestigious Red Dot Award: Product Design 2025 in the category “Bicycles and Bicycle Accessories” for its innovative XS System. This recognition marks the third major design accolade for the company within a short timespan, reinforcing MAHLE’s leadership in the field of intelligent and sustainable e-bike solutions.
The MAHLE XS System impressed the Red Dot jury with its ultra-compact form, minimalist aesthetic, and advanced engineering. Designed for integration into lightweight urban e-bikes, the system exemplifies how minimalism can coexist with high performance. Central to the design is the eX1 battery, which, weighing just over 1 kg, serves as the sole energy source for the system. This strategic approach enables seamless integration into the bike frame, enhancing both the visual appeal and the aerodynamic profile.
Lightweight yet powerful
When paired with MAHLE’s proprietary X20 or X30 motors, the complete drive unit weighs a mere 2.5 kg, yet delivers a robust torque of 55 Nm—comparable to traditional mid-drive motors. This balance of weight and power makes the XS System an appealing choice for urban cyclists seeking efficiency without compromising on performance.
Built with sustainability in mind
In addition to its technical merits, the XS System reflects a strong commitment to sustainability. The product’s design minimizes material usage, and its modular architecture not only supports ease of maintenance but also ensures compatibility with MAHLE’s broader ecosystem. The core system includes essential components such as the eX1 battery, XS controller, motor, and either a torque or PAS sensor, with a suite of accessories available for expanded functionality.
International recognition for innovation
The Red Dot Award follows the XS System’s recent wins at the Design & Innovation Awards and the iF Design Award 2025, positioning MAHLE at the forefront of forward-thinking mobility solutions. These accolades underscore the company’s dedication to creating smart, user-friendly technologies that meet the evolving needs of urban transportation.
Setting a new standard in urban mobility
As the demand for compact, sustainable mobility solutions continues to grow, MAHLE’s XS System sets a new benchmark in the e-bike industry—demonstrating how design excellence and environmental responsibility can go hand in hand.
More information about MAHLE’s XS System can be accessed here.
LEVA EU member MAHLE has achieved the highest rating from the globally recognized Carbon Disclosure Project (CDP) for its climate protection efforts. For the first time, the company has received an “A” grade in the climate protection category, securing a “Leadership” rating, highlighting its strong commitment to sustainability.
The CDP, an independent organisation, evaluates companies worldwide based on their transparency and climate action initiatives. It states that MAHLE has demonstrated significant progress in reducing CO2 emissions, achieving a 47% reduction in emissions from its energy consumption since 2019. Additionally, it has reduced its emissions along the supply chain and during product use (Scope 3) by 17%.
Georg Dietz, a member of the MAHLE Group Management Board, emphasized the importance of this achievement, stating, “This outstanding rating is strong evidence of the successful implementation of our sustainability strategy and an important signal to our customers, business partners, investors and employees.”
Innovative technologies drive sustainability
MAHLE’s environmental success is driven by a range of strategic initiatives, including technological advancements, process optimizations aimed at energy efficiency, and an increased reliance on renewable energy sources.
Kathrin Apel, Head of Sustainability, Health, Occupational Safety, and Environmental Management at MAHLE, highlighted key measures that have contributed to the company’s sustainability progress. “Our progress in climate protection was made possible by replacing fossil fuels with electricity and by increasing the use of recycled and bio-based materials. We are also working intensively with our suppliers to further reduce emissions,” Apel stated.
Expanding sustainability to electric mobility
As well as being a key player in the automotive industry, MAHLE has made strides in sustainable mobility solutions, particularly in the e-bike industry. Its electric bicycle drive systems set new benchmarks for energy-efficient and environmentally friendly transportation solutions, aligning with MAHLE’s broader strategy to support the decarbonization of the automotive industry while exploring additional sustainable transportation options.
Ambitious goals for climate neutrality
MAHLE has set an ambitious target of achieving climate neutrality by 2040. By 2030, the company aims to further reduce emissions along the supply chain and during product use by an additional 28%. Transparency in sustainability reporting remains a key priority, with MAHLE subjecting its energy and emissions data to external audits since 2021.
With its continued commitment to environmental responsibility and innovation, MAHLE remains a powerful force in driving sustainable mobility solutions worldwide.
LEVA-EU member MAHLE SmartBike Systems has been awarded the prestigious iF Design Award 2025 for its innovative XS System, highlighting once again the company’s commitment to design excellence and sustainability in urban mobility.
This important recognition, awarded by one of the world’s most prestigious design awards, underlines the relevance of the XS System in the eBike industry.
Minimalist design revolutionizes urban mobility
The XS System has been awarded for its lightweight, versatile and highly functional design. Weighing just over one kilogram, the eX1 external battery is compatible with any type of bicycle, offering discreet and efficient integration. In addition, it includes USB-C charging through the Energy Hub, which enhances the user experience, ensuring convenience and efficiency.
Innovation and sustainability
The iF Design Award jury highlighted the positive impact on sustainability and the innovative approach of the XS System for urban mobility. With a solution that optimizes design and material consumption, MAHLE has succeeded in creating a system that is not only efficient and powerful, but also minimizes its ecological footprint, reaffirming the company’s commitment to a greener future.
Global recognition and commitment to the future
This award adds to MAHLE’s other major achievements, such as the Design & Innovation Award 2025, consolidating its position as a leader in the field of electric bicycle technology. The iF Design Award 2025 received a total of 10,651 entries in 82 categories from 66 countries, evaluated by 131 expert jurors. This recognition reinforces the importance ofinnovation in the design and sustainability of MAHLE products.
XS System availability and customization
The XS System is now available on the market and offers bicycle manufacturers the possibility of incorporating an advanced solution that allows customization according to user needs, without compromising efficiency or performance.
MAHLE SmartBike Systems is the specialized division for the design and development of drive systems for electric bicycles of the German MAHLE Group, an international leader in sustainable mobility solutions for the present and the future. The team, of more than 150 people, is composed of software and hardware engineers, industrial and electronic engineers, quality specialists, 3D designers, creative, production and materials experts and a long list of professionals to which are added another 80 people distributed in the different centers of the group in Spain, Germany and Asia.
With Palencia as the headquarters of this great project, MAHLE SmartBike Systems brings together MAHLE’s R&D, Marketing, Operations and Sales activities in the electric bicycle sector. The ultralight and compact MAHLE systems are composed of the motor, batteries, controllers, components and all kinds of intelligent solutions for electric bicycles and are perfectly integrated and interconnected with each other to offer the rider a fully customized experience. For all these features, more than 80 brands worldwide, including those whose innovation is revolutionizing the cycling industry, incorporate MAHLE drive systems as the perfect choice in terms of integration, cost and efficiency for electric mobility.
LEVA-EU member Mahle SmartBike Systems saw its X30 System and the XS System receive high recognition from the prestigious bike-industry awards body.
The Design and Innovations Awards 2025 had great praise for both systems (launched in 2024) which won awards in the “Components Road” category
X30 System, an innovation that redefines electric assistance
“The MAHLE X30 system combines intelligent assistance, compact design and advanced connectivity to deliver a natural pedalling experience, tailored to the individual rider.”
Its compact design, light weight and capability bring efficient performance while preserving a natural riding experience, with its discreet integration being ideal for premium eBikes.
XS System, is recognised for revolutionising urban mobility
“The MAHLE XS system redefines eBike technology with simplicity, versatility and minimalist design, offering intuitive assistance, unobtrusive integration and advanced customisation for any type of bike.”
Thanks to its lightweight and versatile design the XS System is a revolution for urban mobility,its eX1 external battery weighs just over a kilo, is a functional match for all types of bike, delivering on simplicity with discreet integration. Its Energy Hub includes USB-C charging for enhanced user convenience and efficiency.
The latest 2025 awards for Mahle follows on from its 2023 success when the brand’s X20 system won a Design and Innovation award for being “considered the lightest eBike system on the market”.
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Revolutionizing eBike Integration
•Setting a new standard for eBike system integration by offering unprecedented freedom in bicycle design •External battery eX1 becomes the sole power source, providing ample energy for daily use applications •Smaller, more efficient batteries promote sustainability by reducing resource consumption •Benchmark power-to-weight ratio •Integration with MAHLE X20 or X30 drive units •Compatible with the full MAHLE SmartBike Systems Ecosystem
MAHLE SmartBike Systems unveils its new XS System setting a new standard for eBike system integration by offering unprecedented freedom in bicycle design. The XS system simplifies eBike integration by eliminating the need for a large internal battery, instead utilizing the compact eX1 external battery as the exclusive energy source. Paired with MAHLE X20 or X30 motors, the system boasts a weight of just 2.5 kilograms with the X20, generating as much torque as a 55 Nm mid-drive. The XS System is compatible with the full MAHLE Ecosystem and is already available in the market.
“Our passion for innovation and commitment to cyclists inspire us to continually push boundaries. With the XS system, we have distilled the eBike down to its most essential elements, delivering unmatched value,” said Jochen Sommer, General Manager of MAHLE SmartBike Systems. Battery integration has long posed a challenge for bike manufacturers due to size and assembly complexities. MAHLE’s XS system solves this by offering a streamlined eBike setup powered entirely by a 1kg external battery, which conveniently fits in a standard water bottle cage. In addition, the newly developed Smart Motor Controller can be mounted inside or outside the frame, allowing for minimalistic, unobtrusive integration—making it possible to use standard muscular bike frames to create fully functional eBikes.
Without sacrificing performance, the XS system is comprised of only the essential components: the eX1 External Battery, XS Smart Controller, X20 or X30 Hub Drive Unit, and a Torque or PAS (Pedal Assist) Sensor. This minimalism reduces the system’s environmental footprint by downsizing components and simplifying the system’s architecture. Furthermore, its ease of maintenance and broad range of accessories provide limitless customization opportunities.
The eX1 battery fits perfectly for daily use, offering over 170Wh of capacity. “In our research, we found that even less than 100Wh are sufficient for most daily activities —urban commuting, short rides—so we focused on optimizing for what riders need. The result is XS: a light, efficient system that perfectly suits everyday use,” said Marco de la Serna, Head of Product, Strategy, and Business Development at MAHLE SmartBike Systems.
Additionally, the eX1 battery serves as a Range Extender for any existing MAHLE X20 or X30 system and as a power bank to charge devices such as phones or laptops thanks to a USB-C port integrated in the Energy Hub charger, which comes along with the system.
The XS system also integrates with the expansive X-series accessory line, enhancing both performance and user experience. Customization is nearly limitless, with optional accessories like the Duo, eShifters, and Pulsar ONE, among others, available for added functionality.
Users can also connect to the MAHLE Digital Ecosystem via their eBike, laptop, smartphone, or Apple Watch, opening the door to the present and future of the smartbike revolution. The MAHLE digital ecosystem enables a multitude of functionalities, providing a perfect symbiosis between user and eBike.
Using the system is very intuitive. With an intuitive control, riders can power on the system, switch between assistance modes, and monitor battery levels directly from the interface atop the eX1 External Battery. The system also offers automatic assistance, enhancing ease of use.
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On September 6th, e-bike drive systems provider MAHLE launched the MAHLE Energy Hub, a new platform that upgrades its External Battery eX1.
MAHLE’s Energy Hub boosts its External Battery eX1 (formerly known as Range Extender e185) to be even more convenient for users, easing its charging while transforming it into a multi-functional energy source that can be shared by other devices.
The brand describes its MAHLE Energy Hub as “the best travel partner” for charging anytime and anywhere, including inhospitable places off the beaten track. It makes the External Battery eX1 more versatile, even in the off-season, enabling it to be used as a high-capacity power bank.
The Energy Hub comes with a standard USB-C cable and protective cover. Here are its specifications.
More information about the MAHLE Energy Hub can be accessed here.
