German supplier Mahle prepares to launch OEM-quality high-voltage charging parts and diagnostic tools in 2025, addressing reliability issues and supporting the growing EV servicing sector and infrastructure expansion.

German automotive supplier Mahle is gearing up to enter the global electric vehicle (EV) aftermarket with a pretty innovative lineup of high-voltage charging components—so, basically, they’re expanding beyond their traditional role in original equipment manufacturing (OEM). Starting in 2025, Mahle has plans to roll out input filters from October and onboard chargers (OBCs) by the end of that year. At first, these will be fitted into models from brands like Renault, Peugeot, Citroën, DS, and Opel. These components—they handle converting AC from the grid into DC for EV batteries and also keep systems safe from voltage spikes during charging—are directly from Mahle’s OEM operations, so they meet the highest quality standards, no doubt about that.

Mahle really emphasizes how important high-voltage parts are becoming in the EV spare parts and servicing market. After all, these components tend to degrade over time due to factors like aging, vibration, moisture getting in, and overheating—as you might expect with electrical systems under constant stress. The company is predicting strong demand in the aftermarket, which makes sense, considering the rapid growth of EV fleets and the maintenance they’ll require. They also plan to introduce more power electronics and high-voltage parts throughout 2026, soon broadening their portfolio to cover a wider range of vehicle types.

This step basically fills a crucial gap in the market, especially as EV adoption accelerates worldwide. Workshop networks will need OEM-quality parts to properly repair and maintain electric and plug-in hybrid vehicles. Dr. Armin Messerer, who’s the Head of Product Management and Purchasing at Mahle Lifecycle and Mobility, explains that this move will benefit both workshops and end users—since Mahle’s deep roots in OEM technology in drive systems, charging, and thermal management are now reflected comprehensively in services and spare parts.

That said, Mahle’s aftermarket launch comes at a pretty relevant time, especially considering some recent reports about reliability issues with their onboard chargers installed in certain Stellantis vehicles. For instance, Leipzig-based rental operator Nextmove revealed that roughly one in three Opel Corsa-e vehicles in their fleet had experienced charger failures. These issues have led to costly replacements—sometimes over €2,000—and long downtimes, which is obviously a real headache. Independent repair specialists like EV Clinic have also documented recurring problems with these chargers. To me, all this highlights just how critical it is for the aftermarket to have robust, reliable components that meet OEM standards—not just average parts.

Looking ahead, Mahle will showcase its expanded solutions for electric mobility at the upcoming IAA Mobility 2025 in Munich. Among the highlights will be their TechPRO® 2 diagnostic tool, now featuring artificial intelligence, and the E-HEALTH-Charge battery diagnostic system. This new system can diagnose high-voltage batteries rapidly—under 15 minutes—providing workshops with important info like battery health, error codes, and safety parameters without needing an extremely technical background beforehand.

In addition, Mahle is advancing their presence in EV charging infrastructure. They’ve secured a series order for a high-performance cooling module designed for megawatt charging stations that serve electric commercial vehicles. This cooling module, which should go into production by late 2025, addresses the critical thermal management challenge faced by fast chargers—supporting rapid charging capacities up to 3.75 megawatts. Its modular design and flexible application mean it isn’t just for passenger cars but also for light commercial vehicles, maritime, and rail systems. Clearly, Mahle is committed to covering extensive parts of the EV ecosystem.

All these initiatives really show Mahle’s strategic focus on blending their extensive expertise in electrification, thermal management, and power electronics to support the increasing demands of the EV aftermarket and charging infrastructure. As repair shops face mounting complexity and a higher volume of electric vehicle repairs, having access to OEM-level high-voltage parts and diagnostic tools will be absolutely crucial for ensuring reliable, quick service—so the growth of electric mobility can stay sustainable and efficient.

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Source: Noah Wire Services