BorgWarner has won a program award from a premium European original equipment manufacturer (OEM) to supply an advanced 800V Integrated Drive Module (iDM) for a Range Extended Electric Vehicle (REEV). Mass production of the system is scheduled to begin in 2029.
The award reinforces BorgWarner’s expanding role in high-voltage electrification technologies and hybrid propulsion systems as global automakers accelerate their transition toward next-generation new energy vehicles.
Highly Integrated 800V Drive Module for REEV Applications
The awarded iDM solution features a highly integrated architecture built around BorgWarner’s innovative single-electric-machine design that combines generator and propulsion functions into one compact system. By merging two major REEV functionalities into a single unit, the design enables optimized vehicle packaging, reduced system complexity, and improved efficiency.
The system integrates an inverter, dual clutches, a dual-mass flywheel, and works at the system level alongside the vehicle’s internal combustion engine. In addition to delivering energy-efficient generator operation, the module supports an all-wheel-drive mode when required, enhancing vehicle versatility and performance.
Advanced Power Electronics for High-Voltage Performance
The inverter incorporates BorgWarner’s next-generation Viper power switches along with dual-side cooled power module technology. Developed specifically for high-performance electric drive applications, the platform is engineered to deliver strong electrical efficiency and advanced thermal management capabilities.
Operating at 800V, the system is designed to meet demanding high-voltage and high-current requirements, supporting faster charging, improved power density, and enhanced drivetrain performance – all critical factors in modern hybrid and electrified vehicle architectures.
Strengthening Electrification Capabilities
BorgWarner continues to leverage its full-stack in-house capabilities across electric motors, driveline systems, power electronics, software controls, and system integration. With proven product quality, localized manufacturing expertise, and close collaboration with OEM partners, the company aims to provide flexible and scalable electrification solutions tailored to evolving market demands.
“Securing this program award underlines BorgWarner’s strength in electric drive technology and system integration,” said Dr. Stefan Demmerle, Vice President of BorgWarner Inc. and President and General Manager, PowerDrive Systems. “With the China team taking the lead and collaborating with a global team, we have created a highly integrated solution that balances performance, efficiency, and packaging. We are proud to support our customer with innovative technology for its next-generation range extended vehicles.”
The new program underscores BorgWarner’s strategic positioning in the hybrid range-extended segment, as automakers explore efficient transitional powertrains that balance electric propulsion with extended driving range.
Also read – BorgWarner Enters Data Centre Market with Modular Turbine Generator System Award
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