Electric Vehicle Range Extender Market Research Report Information By Technology (Internal Combustion Engine (ICE) Range Extender, Fuel Cell Range Extender), By Vehicle Type (Passenger Cars, Commercial Vehicles (Light Commercial Vehicles, Heavy Commercial Vehicles)), By Application (Fleet Vehicles, Public Transport Vehicles, Personal Vehicles) and Region (North America, Europe, Asia-Pacific, South & Central America, Middle East & Africa) - Forecast till 2035

Global Electric Vehicle Range Extender Market Overview

The Electric Vehicle Range Extender Market was valued at USD 1.59 Billion in 2024. The Electric Vehicle Range Extender Market industry is projected to grow from USD 1.86 Billion in 2025 to USD 6.82 Billion by 2035, exhibiting a compound annual growth rate (CAGR) of 13.9% during the forecast period (2025-2035).

The increasing demand for longer driving ranges in electric vehicles, advancements in battery technology enhancing range extender efficiency and government incentives and policies promoting electric vehicle adoption are driving the growth of the Electric Vehicle Range Extender Market.

As per the Analyst at MRFR, the electric vehicle (EV) range extender market is experiencing robust growth due to the rising consumer demand for EVs with extended driving ranges, particularly for long trips or in areas with limited charging infrastructure. Technologies like hybrid powertrains and hydrogen fuel cells, such as Allison’s eGen Flex and Mercedes-Benz’s eCitaro Fuel Cell, address range anxiety, enhancing reliability for industries like public transit and logistics. 

Government incentives in regions like Norway, China, and the EU, alongside innovations in battery and fuel cell efficiency, further propel adoption. However, advancements in battery technologies, high initial costs, and consumer skepticism about reliability challenge growth, while collaborations and sustainable solutions offer opportunities.

 FIGURE 1: ELECTRIC VEHICLE RANGE EXTENDER MARKET VALUE (2019-2035) USD BILLION

Source: Secondary Research, Primary Research, Market Research Future Database, and Analyst Review

Electric Vehicle Range Extender Market Opportunity

Collaborations Between Automotive Companies and Battery Manufacturers

Collaborations between automotive companies and battery manufacturers are pivotal in advancing the electric vehicle (EV) range extender market, enhancing efficiency and scalability. In 2024, SAIC Motor partnered with Audi to co-develop high-end EVs using SAIC’s intelligent electric architecture, integrating range extender technologies for premium models. Similarly, Stellantis entered a €4.1 billion joint venture with Contemporary Amperex Technology Co., Limited (CATL) to establish a lithium iron phosphate (LFP) gigafactory in Spain, supporting range-extended vehicles like the Ram 1500 Ramcharger. 

Hyundai Mobis collaborates with battery suppliers for its EREV powertrains, targeting over 530 km range for models like the Santa Fe by 2028–2029, leveraging its Metaplant America facility. Ceres Power’s partnership with Nissan and M-Solv, supported by Innovate UK, focuses on solid oxide fuel cell (SOFC) range extenders using biofuels. These alliances combine automotive expertise with advanced battery and fuel cell technologies, addressing range anxiety and infrastructure gaps. By pooling resources, companies reduce R&D costs, accelerate innovation, and ensure compatibility with diverse vehicle platforms, strengthening their competitive edge in the global EV market.

Electric Vehicle Range Extender Market Segment Insights

Electric Vehicle Range Extender by Technology Insights

Based on technology, the Electric Vehicle Range Extender Market has been segmented into Internal Combustion Engine (ICE) Range Extender, Fuel Cell Range Extender. The Internal Combustion Engine (ICE) Range Extender segment dominated the global market in 2024, while the Fuel Cell Range Extender segment is projected to be the fastest–growing segment during the forecast period. Internal Combustion Engine (ICE) range extenders are auxiliary engines used in electric vehicles (EVs) to generate electricity and recharge the battery once it is depleted, thereby extending the vehicle’s driving range. 

These systems are especially useful in range-extended EVs, where electric motors drive the wheels, but a small ICE steps in when needed. Several models have employed ICE range extenders with varying engine sizes. The BMW i3 Range Extender features a compact 0.6-liter two-cylinder gasoline engine designed to maintain the battery charge when it drops below a certain level, effectively doubling the vehicle's range without directly powering the wheels. The Chevrolet Volt, on the other hand, uses a 1.5-liter four-cylinder engine. It operates similarly, generating electricity to support continued driving once the initial electric range is depleted.

FIGURE 2: ELECTRIC VEHICLE RANGE EXTENDER MARKET SHARE BY TECHNOLOGY 2024 AND 2035 (USD BILLION)

Source: Secondary Research, Primary Research, MRFR Database and Analyst Review

Electric Vehicle Range Extender by Vehicle Type Insights

Based on vehicle type, the Electric Vehicle Range Extender Market has been segmented into Passenger Cars, Commercial Vehicles (Light Commercial Vehicles, Heavy Commercial Vehicles). The Passenger Cars segment dominated the global market in 2024, while the Commercial Vehicles segment is projected to be the fastest–growing segment during the forecast period. The Indian electric passenger vehicle (EV) market achieved a record-breaking 99,068 units sold in CY2024, a 20% increase from 82,563 units in CY2023. 

This growth, due to the wallet-friendly EVs like SUVs, sedans, and hatchbacks, reflects a shift toward e-mobility despite higher upfront costs compared to petrol or diesel vehicles. From 2015 to 2024, nearly 250,000 electric PVs were sold in India, with October 2024 marking the peak at 11,361 units, up 49% year-on-year. However, increased competition has reduced market leader Tata Motors’ share to its lowest in three years.

Electric Vehicle Range Extender by Application Insights

Based on Application, the Electric Vehicle Range Extender Market has been segmented into Fleet Vehicles, Public Transport Vehicles, Personal Vehicles. The Fleet Vehicles segment dominated the global market in 2024, while the Personal Vehicles segment is projected to be the fastest–growing segment during the forecast period. Fleet vehicles represent one of the most promising applications for EVs with range extenders in India’s evolving commercial mobility landscape. 

Operating across logistics, last-mile delivery, urban transport, and corporate mobility, fleets demand high uptime, route flexibility, and predictable cost of ownership. While full battery electric vehicles (BEVs) are gaining traction, range limitations and inadequate charging infrastructure continue to hinder their adoption for longer or variable routes. 

EVs with range extenders offer a practical solution by combining the benefits of electric drivetrains—such as lower emissions and quieter operation—with the reliability of an auxiliary power unit that kicks in once the battery depletes. This hybrid setup ensures vehicles can complete long shifts without range anxiety or extended charging downtime, which is critical for fleet operators prioritizing operational efficiency.

Electric Vehicle Range Extender Regional Insights

Based on the Region, the global Electric Vehicle Range Extender is segmented into North America, Europe, Asia-Pacific, South & Central America and Middle East & Africa. The North America dominated the global market in 2024, while the Asia Pacific is projected to be the fastest–growing segment during the forecast period. Major demand factors driving the North America market are the increasing demand for electric vehicle (EV) range extenders in North America is growing due to the combination of consumer needs, infrastructure limitations, and supportive policies. 

Range extenders, such as internal combustion engines (ICE) or fuel cell systems, address range anxiety—a key barrier to EV adoption—by providing additional driving distance beyond the primary battery’s capacity. This is particularly relevant in North America, where long-distance travel is common, and charging infrastructure, while expanding, remains uneven, especially in rural areas.

FIGURE 3: ELECTRIC VEHICLE RANGE EXTENDER MARKET VALUE BY REGION 2024 AND 2035 (USD BILLION)

Source: Secondary Research, Primary Research, MRFR Database, and Analyst Review

Further, the countries considered in the scope of the Application Tracking System Market are the US, Canada, Mexico, Germany, UK, France, Russia, Italy, Spain, Rest of Europe, China, India, Japan, South Korea, Malaysia, Thailand, Indonesia, Rest of APAC, Brazil, Argentina, Rest of South & Central America, GCC Countries, South Africa, Rest of Middle East & Africa and others.

Global Electric Vehicle Range Extender Key Market Players & Competitive Insights

Many global, regional, and local vendors characterize the Electric Vehicle Range Extender Market. The market is highly competitive, with all the players competing to gain market share. Intense competition, rapid advances in technology, frequent changes in government policies, and environmental regulations are key factors that confront market growth. The vendors compete based on cost, product quality, reliability, and government regulations. Vendors must provide cost-efficient, high-quality products to survive and succeed in an intensely competitive market.

The major competitors in the market are Mahle GMBH, Saic Motor Corporation Limited, Hyundai Mobis, ZF Friedrichshafen Ag, Ballard Power Systems, Magna International Inc, Toyota Motor Corporation, Allison Transmission, Ceres, Schaeffler Ag, Nissan Motor Co., Ltd, Cosworth, HYLIION Inc, Ab Volvo, Stellantis are among others. The Electric Vehicle Range Extender Market is a consolidated market due to increasing competition, acquisitions, mergers and other strategic market developments and decisions to improve operational effectiveness.

Key Companies in the Electric Vehicle Range Extender Market include

• Mahle GMBH
• Saic Motor Corporation Limited
• Hyundai Mobis
• ZF Friedrichshafen Ag
• Ballard Power Systems
• Magna International Inc
• Toyota Motor Corporation
• Allison Transmission
• Ceres
• Schaeffler Ag
• Nissan Motor Co., Ltd
• Cosworth
• HYLIION Inc
• Ab Volvo
• Stellantis

Electric Vehicle Range Extender Industry Developments

• Q2 2025: ZF further develops electric range extender systems, production starts in 2026 ZF announced the introduction of its new generation electric vehicle range extender technology, with volume production scheduled to begin in 2026. The system is designed to address range anxiety and meet growing global demand for flexible EV drive concepts.
• Q2 2025: BMW to reintroduce range extender in next-generation X5, collaborating with ZF BMW is reportedly planning to launch a new X5 model with a range extender (iX5 REx) in collaboration with ZF, targeting a 621-mile total range. The U.S. market is expected to be among the first recipients, with production at the Spartanburg, South Carolina plant.

Electric Vehicle Range Extender Market Segmentation

Electric Vehicle Range Extender by Technology Outlook

• Internal Combustion Engine (ICE) Range Extender
• Fuel Cell Range Extender

Electric Vehicle Range Extender by Vehicle Type Outlook

• Passenger Cars
• Commercial Vehicles
  • Light Commercial Vehicles
  • Heavy Commercial Vehicles

Electric Vehicle Range Extender by Application Outlook

• Fleet Vehicles
• Public Transport Vehicles
• Personal Vehicles

Electric Vehicle Range Extender Regional Outlook

• North America
  • US
  • Canada
  • Mexico
• Europe
  • Germany
  • UK
  • France
  • Russia
  • Italy
  • Spain
  • Rest of Europe
• Asia-Pacific
  • China
  • India
  • Japan
  • South Korea
  • Malaysia
  • Thailand
  • Indonesia
  • Rest of Asia-Pacific
• South & Central America
  • Brazil
  • Argentina
  • Rest of South & Central America
• Middle East & Africa
  • GCC Countries
  • South Africa
  • Rest of the Middle East & Africa

Report Attribute/Metric	Details
Market Size 2024	USD 1.59 Billion
Market Size 2025	USD 1.86 Billion
Market Size 2035	USD 6.82 Billion
Compound Annual Growth Rate (CAGR)	13.9% (2025-2035)
Base Year	2024
Forecast Period	2025-2035
Historical Data	2019-2023
Forecast Units	Value (USD Billion)
Report Coverage	Revenue Forecast, Competitive Landscape, Growth Factors, and Trends
Segments Covered	By Technology, By Vehicle Type, By Application
Geographies Covered	North America, Europe, Asia Pacific, South & Central America, Middle East & Africa
Countries Covered	The US, Canada, Mexico, Germany, UK, France, Russia, Italy, Spain, Rest of Europe, China, India, Japan, South Korea, Malaysia, Thailand, Indonesia, Rest of APAC, Brazil, Argentina, Rest of South & Central America, GCC Countries, South Africa, Rest of Middle East & Africa
Key Companies Profiled	Mahle GMBH, Saic Motor Corporation Limited, Hyundai Mobis, ZF Friedrichshafen Ag, Ballard Power Systems, Magna International Inc, Toyota Motor Corporation, Allison Transmission, Ceres, Schaeffler Ag, Nissan Motor Co., Ltd, Cosworth, HYLIION Inc, Ab Volvo, Stellantis
Key Market Opportunities	·         Collaborations between automotive companies and battery manufacturers ·         Development of innovative and cost-effective range extender models
Key Market Dynamics	·         Increasing demand for longer driving ranges in electric vehicles ·         Advancements in battery technology enhancing range extender efficiency