BorgWarner has secured a significant contract from a major North American original equipment manufacturer (OEM) to supply an advanced 800-volt secondary Integrated Drive Module (iDM) along with a generator module featuring a dual inverter. The systems will power a new lineup of range-extended electric vehicle (REEV) trucks and large-frame SUVs, with production scheduled to begin in 2029.
The award marks a key milestone for BorgWarner, including the introduction of its next-generation Viper power module technology in a high-volume vehicle program.
800V Integrated Drive Module for High-Performance REEV Platforms
BorgWarner’s 800V iDM is a scalable two-in-one solution integrating an induction electric machine and gearbox within a compact architecture. Designed for hybrid and electric vehicle applications, the module delivers high torque density and efficient performance while meeting the demanding packaging constraints of large SUVs and trucks.
By leveraging a torque-dense induction e-machine, the iDM eliminates the need for permanent magnets, helping support supply chain resilience and cost optimization. The compact design was engineered to fit within limited packaging space shared with the internal combustion engine (ICE), while still exceeding performance, torque, and efficiency requirements.
Generator Module with Dual Inverter and Viper Technology
Complementing the iDM is a generator module that incorporates a permanent magnet electric machine paired with a dual inverter mounted directly to the ICE. This configuration enables extended driving range while maintaining electric vehicle performance characteristics.
A critical innovation within the generator module is BorgWarner’s next-generation Viper power switch technology. The dual inverter design leverages this proprietary, highly power-dense module to achieve optimized system efficiency within a smaller and more cost-effective footprint.
Together, the integrated drive and generator modules enable REEV platforms to combine the benefits of electric propulsion with the flexibility and availability of an internal combustion engine when required.
Expanding North American Electrification Capabilities
This program highlights BorgWarner’s broad propulsion portfolio, spanning electric motors, inverters, power modules, gearboxes, and system integration. The contract strengthens the company’s electrification presence in North America while reinforcing its role as a key technology partner for automakers transitioning to advanced hybrid and electric architectures.
With production slated for 2029, the award positions BorgWarner at the forefront of high-voltage REEV innovation in the full-size truck and SUV segment, a category increasingly central to the evolution of electrified mobility.
Leadership Quote
“This business win showcases our breadth in the propulsion space in North America, accentuating our innovative design and manufacturing capabilities to deliver a full motor portfolio from platform-based, high performing and efficient drive units to inverters, e-machines, control boards and more,” said Dr. Stefan Demmerle, Vice President of BorgWarner Inc. and President and General Manager of BorgWarner PowerDrive Systems. “We’re grateful for the opportunity to carry on our strong, collaborative relationship with this highly respected OEM.”
Also read – BorgWarner Secures 800V Integrated Drive Module Program for Premium European OEM
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