“TraXon 2 Hybrid delivers a clear advantage for high‑mileage operations by substantially reducing CO2 emissions while maintaining cost efficiency,” said Christian Feldhaus, vice president of transmissions and hybrids at ZF Commercial Vehicle Solutions. “Based on our ongoing discussions with vehicle manufacturers, fleet operators and industry bodies, we see hybrid technologies providing a clear and practical pathway toward significant emissions reduction in future heavy‑duty transport.”

Emissions-saving technology

The TraXon 2 Hybrid builds on the all-electric TraXon 2 platform. The hybrid system enables electric-only driving in urban zones while retaining combustion operation for long-distance transportation.

ZF test evaluations confirmed that the system supports substantial CO2 reductions in long-haul and distribution applications when operated with consistent recharging. The PHEV system can reduce CO2 emissions by up to 47% in long-haul transportation and up to 73% in distribution transportation. This supports the European fleet emissions targets for 2030 and provides flexibility for future toll and tax regulations.

The TraXon 2 Hybrid builds on ZF’s e-mobility platform, which includes electric central drives such as CeTrax 2 and AxTrax 2 e-axles, and supports applications where full electrification is not yet practical across all routes. For fleets with limited investment capacity, it also enables a gradual transition to electrification, including operational, dispatch and charging adjustments.

The hybrid platform integrates an in-house-developed electric motor and operates at 600-800V, with 190kW continuous power and higher peak output. Positioned in a P2 layout between the clutch and transmission, the electric motor enables pure electric driving up to 12th gear and supports regenerative braking for improved efficiency. The combustion engine operates according to the vehicle’s driving strategy and provides range for long-haul applications. The system is designed to improve overall efficiency and reduce CO2 emissions while retaining the range and refueling flexibility of a combustion engine. It can be combined with diesel, HVO/e-fuels, CNG/LPG and hydrogen combustion engines.

In related news, Agillence and Toyota Motor Europe partner on logistics optimization software

The hydrogen-powered trucks use high-pressure, direct injection (HPDI) technology, which the company says improves energy efficiency, reduces fuel consumption and increases engine power compared with conventional hydrogen combustion engines. HPDI works by injecting a small amount of ignition fuel at high pressure to enable compression ignition before hydrogen is added. Volvo already uses this technology in its gas-powered trucks, with over 10,000 units sold worldwide.

The hydrogen engine technology is derived from its diesel powertrain, delivering “diesel-like performance” while substantially cutting CO₂ emissions, the auto maker said.

“On-road testing is an important milestone for our hydrogen combustion engine trucks. I feel confident that they will be the best in the industry if you look at fuel efficiency, power, torque and drivability,” said Jan Hjelmgren, head of product management at Volvo Trucks. “Customers will be able to operate them just like diesel trucks. Our experience with HPDI technology in more than 10,000 gas-powered trucks is strong proof of its performance.”

Hydrogen combustion engine trucks will be especially suitable over longer distances and in regions where there is limited charging infrastructure or time for the recharging of battery-electric trucks.

Volvo trucks with combustion engines powered by green hydrogen have the potential to deliver net-zero CO₂ well-to-wheel when using renewable HVO as ignition fuel. They are categorized as Zero Emission Vehicles (ZEV) under the agreed EU CO₂ emission standards.

The hydrogen-powered combustion engine trucks will complement the company’s offering of other alternatives, such as battery electric trucks, fuel cell electric trucks and trucks that run on renewable fuels, like biogas and HVO (hydrotreated vegetable oil).

“We see great potential for hydrogen combustion engine trucks and they will have a role to play in the transformation to zero-emission transport,” said Hjelmgren. “Several technologies will be needed to decarbonize. As a global truck manufacturer we offer a variety of decarbonization solutions and help our customers choose the best alternative based on transport assignment, available infrastructure and green energy prices.”

Related news, Swiss Council for Accident Prevention joins Euro NCAP as affiliate member

AVL VSM is a flexible, real-time simulation tool that enables users to model components, systems and complete vehicles. It allows them to test vehicle dynamics and performance in realistic scenarios, which is crucial for optimizing vehicle characteristics and ensuring safety. VSM enables a more integrated approach to vehicle design and optimization by allowing simultaneous consideration of various vehicle attributes and components and how they interact.

When VSM is paired with an Ansible Motion driver-in-the-loop simulator, the user can test changes to the virtual model and refine chassis dynamics, powertrain driveability, ADAS and active safety function calibration with a virtual test drive.

“By combining AVL VSM with Ansible Motion driver-in-the-loop simulators, manufacturers can move critical decisions to the front of the development cycle, dramatically reducing physical prototypes and test iterations,” said Gary Newton, AVL’s vice president of business development. “This tool combination can have an enormous impact on timeline and budget. Imagine validating 70+ track scenarios per day in multiple conditions, surfaces and drive events. The result isn’t incremental improvement, it’s months saved and millions preserved.”

Salman Safdar, Ansible Motion’s business development director, added, “Through our continuing collaborative efforts with AVL, we’re developing new ways to conduct subjective and objective evaluations of qualified concepts much earlier in the vehicle design cycle. Connecting our simulators seamlessly with a feature-rich simulation environment like AVL VSM elevates the virtual vehicle development process for manufacturers seeking to shorten development times, realize cost savings and reduce environmental impacts.”

Related news, GRAS launches new KEMAR head and torso simulator for acoustics analysis

The super-high-performance powertrain has been built to meet the new demanding 2026 F1 regulations for smaller, lighter, more nimble cars and increased on-track competitiveness. As the exclusive metrology partner, Hexagon’s support of Oracle Red Bull Racing and Red Bull Ford Powertrains covers the whole car, chassis and engine, enabling trackside refinements and up to 30,000 car design changes per season. Using coordinate measuring machines (CMMs), 3D laser scanners and software, Hexagon helped achieve the sub-micron tolerances required for manufacturing, testing and assembling the V6 turbo hybrid powertrain.

While the new rules increase reliance on electrical energy, altered aerodynamics and changes to wings will produce less downforce, placing performance demands on the car’s power unit. The front wings are simplified, while the undersides of cars have lost Venturi tunnels that generated a huge amount of grip.

Metrology technologies

Since the start of engine production four years ago, Hexagon has provided high-precision metrology technologies – including the Leitz PMM-C Precision CMM and Leica Absolute Scanner AS1. According to Hexagon, these technologies have accelerated testing and inspection throughout R&D, from prototyping and test-rig evaluation to full production at Red Bull Ford Powertrains’ Milton Keynes facility.

The Leitz PMM-C CMMs are used right across the manufacturing and build areas and are the only equipment capable of dealing with the accuracy, repeatability and flexibility that Red Bull Ford Powertrains requires in power unit manufacture. The portable AS1 3D scanner is used with an Absolute Arm to scan the outer surfaces of the power unit’s crankcases and energy recovery system (ERS) installations for quality control.

“Hexagon’s shared passion for extreme accuracy and performance has been vital to this ambitious project,” said Ben Hodgkinson, technical director, Red Bull Ford Powertrains. “With every element built from scratch, Hexagon’s metrology expertise has enabled us to achieve the tolerances and the levels of quality we require in a cutting-edge piece of engineering to perform at the top level of motorsport. We’re very selective about who we work with and never stop pushing the boundaries – striving for that extra millisecond in performance. We know that Hexagon will support us on that ultra-competitive quest.”

Digitalization

Hexagon has helped Red Bull Ford Powertrains integrate quality inspection and digital 3D models into its engineering processes. Measurement data is captured in QUINDOS, Hexagon’s metrology software for complex geometries such as gears and blades, and, where needed, transferred to Q-DAS for statistical trend analysis. This integrated approach enables CNC machine monitoring and provides corrective feedback to ensure components are manufactured correctly the first time.

Oracle Red Bull Racing, which develops the chassis, also uses Hexagon technology. Continuing a 19-year partnership, it uses Hexagon technology, such as laser trackers, to ensure precise setup and power unit assembly for new vehicles throughout the racing season. Hexagon’s 3D laser scanning and trackside support are vital for ongoing aerodynamic refinements, providing the precision needed to maximize performance on every race weekend. The Oracle Red Bull Racing team has previously reduced faults by 50% using Hexagon technology over a 24-month period.

“Hexagon’s portable metrology technologies will ensure the correct car setup and power unit assembly for the new season vehicles, building on our 19-year partnership with Oracle Red Bull Racing,” commented Emanuel Viklund, president of the portable metrology division at Hexagon.

“Working with Red Bull Ford Powertrains this season is incredibly exciting for all of us at Hexagon. Together, we have engineered and built a powertrain unit under immense pressure. Designed for peak performance, the DM-01 powertrain is now ready to prove itself on the track.

“But nothing in F1 stands still – there is always a new challenge to tackle, a fraction of a second to gain and an opportunity to refine the car to push the limits of precision and performance. We are proud to support them every step of the way.”

Related news, Porsche provides an update on the development of its Formula E Gen4 race car

The fully electric drivetrain provides long-range, high-charging performance with 800V technology and efficient energy recuperation, making the BMW M Neue Klasse a versatile everyday vehicle. Its newly developed architecture, featuring centrally controlled individual wheel drive, reportedly opens a new dimension in driving dynamics and enhances the safety of all next-generation BMW M vehicles.

The Neue Klasse’s advanced central control and electronics architecture also improves the driving dynamics. Four high-performance computers, called Superbrains, manage driving functions, automated driving, infotainment and comfort features. This setup enhances performance through faster data exchange and allows next-generation BMW M models to receive quicker updates and upgrades.

BMW M eDrive concept

The BMW M Neue Klasse has been developed from the ground up. At the core of the new architecture is BMW M eDrive, which is based on the BMW Gen6 technology of the Neue Klasse.

BMW says that M Dynamic Performance Control, using M-specific Heart of Joy software, enhances driving dynamics, safety, traction, recuperation and responsiveness.

The Neue Klasse features two electric drive units on the front and rear axles, each with one electric motor per wheel. Each of the four electric motors drives one wheel. This combines the advantages of rear-wheel and all-wheel drive while enhancing driving dynamics on the road and racetrack. Additionally, the front axle can be completely decoupled.

BMW M eDrive’s electric drive units are BMW M’s most powerful, with parallel motors powering each wheel via dedicated gearboxes. The drive units also integrate the inverter for controlling the electric motors and the oil supply. The system enables precise control of torque and power at each wheel, enabling optimal traction, continuous torque distribution between the braking system and electric motors, and brake energy recuperation right up to the limit.

High-voltage battery

The high-voltage battery, boasting over 100kWh of usable energy as the powerhouse for the BMW M eDrive system, has been adapted to meet the demands of high-performance vehicles.

With a focus on compatibility with both road and racetrack use, BMW’s Design to Power approach uses a performance-optimized Gen6 cylindrical cell with an enhanced cooling system and the Energy Master control unit, enabling higher power outputs for road and track use. With BMW M-specific solutions, the Gen6 high-voltage battery in the fully electric high-performance models delivers even greater peak and charging performance. Additionally, within the Gen6 technology, the Neue Klasse models offer the highest recuperation values. The high-voltage battery housing also serves as a structural component of the vehicle and is connected to the front and rear axles. The resulting higher stiffness leads to improved driving dynamics.

In related news, Czinger establishes UK base at Mira Tech Park

Tyrone Johnson, managing director at Hyundai Motor Europe Technical Center, said, “The investment at Square Campus is a clear sign of our commitment to the region and reflects the importance of Europe in our long-term growth strategy. The extensive new capabilities at HMETC give us more independence and flexibility, while creating exciting new opportunities for collaboration between our brands. Fundamentally, Square Campus will also support us as we continue to grow our market share in Europe, developing new vehicles and technologies designed around the needs of our customers.”

New capabilities

The 25,000m² site is equipped with the largest semi-anechoic chamber within the Hyundai group, enabling unrestricted noise, vibration and harshness (NVH) and drive-by noise testing with complete independence from weather conditions.

Highly advanced dyno facilities at Square Campus play a key role in development, enabling the comprehensive testing of vehicles and individual components, compatible with all-electric, hybrid and internal combustion engine (ICE) powertrain applications. The facility is also equipped with an EV charging laboratory, a state-of-the-art driving simulator and new facilities for extended electronics system development – including over-the-air-updates (OTA), cybersecurity, and advanced driver assistance systems.

In related news, Site visit: Inside Mercedes-Benz’s light testing tunnel

The Future of Automotive Testing Conference

This day of high-level content will explore various topics and provide an engaging opportunity to learn from and connect with industry peers. Situated among the exhibits, it will have a relaxing atmosphere, and visitors will be able to dip in and out at their leisure. A highlight will be ATTI’s on-stage interview with Jon Quigley, who worked for Volvo for many years and now runs his own company, Value Transformation. With his broad experience and portfolio of contacts, he’s a very good person to know. He loves sharing his thoughts, too, hence his new gig as ATTI’s regular columnist.

Read Quigley’s latest column on p36 of the September issue.

Also during the conference, Venkat Adusumalli, software engineering manager at Stellantis, will reveal how Stellantis is using AI to accelerate E/E system testing and validation workflows. Click here for a pre-show interview with him.

Innovation Showcase

The free-to-attend Innovation Showcase also provides an interactive platform for learning about new technologies. Speakers will welcome questions and discussion after their presentations, making it a great way to explore ideas together. Like the conference, it will take place within the main hall, so it will be very easy to listen in while wandering through the exhibits, or to come and go throughout the day.

Technology debuts

The industry is moving quickly and it can be a challenge to keep up. Every year there is an abundance of new technologies on display. Some are incremental improvements to existing products, others are entirely new. It’s always surprising how companies find ways around bottlenecks. Often, these developments emerge from ongoing conversations between supplier and customer, ultimately benefiting multiple companies.

Read ATTI‘s comprehensive expo preview in the September issue.

Face-to-face discussions  

It sounds obvious, but the most fruitful conversations are usually the ones that happen in person – it’s how journalists find the best stories. Year after year, exhibitors and visitors report having forged unexpected collaborations at the show, in the form of technology tie-ups or service partnerships.

Detroit’s revival 

A lot of money has been plowed into Detroit in recent years, as evidenced by the stunning renovation of Michigan Central Station, which is well worth a visit. Much of the investment has been in the tech sector. Eleven years ago – when the station was still derelict – ATTI took a tour of some of the labs at GM and what was then the FCA headquarters (see The right wave length, November 2014, Seasonal highlights, September 2015, and Powerbase, March 2015). The facilities were impressive then and are even more so now, thanks to several years of investment in innovation leading to Detroit’s resurgence as an automotive powerhouse.

Visit the Automotive Testing Expo North America website to secure your FREE pass, which will give you access to the expo, the Future of Automotive Testing Conference and the Innovation Showcase

FISITA’s World Mobility Conference (WMC) 2025 was held at the Palau de Congressos de Catalunya on June 3-5, delivering insight, strategy and technical discussions. Co-located with EuroBrake, it covered the future of technology in mobility, industry disruption, sustainability, regulations, trust, public acceptance and human factors. CEOs from Hyundai Motor Company, VinFast and Chery contributed keynote addresses, while technical sessions focused on model-based system engineering; AI and automation in product development; innovations in vehicle simulation and durability testing, and more.

During The Future of Automotive Testing Conference on October 22 at this year’s Automotive Testing Expo North America (October 21-23), FISITA’s North America ambassador, Scott Craig, will lead a panel discussion titled, Driving validation: The nexus of physical testing, digital twins and global data in the age of SDVs and electrification.

Conference highlights

Jose Manuel Barrios, FISITA executive board member, STA president and head of innovation at Applus Idiada, gave the opening address on a new mobility era marked by electrification, digitalization and automated driving capabilities through connected solutions: “We must balance tradition with innovation, developing holistic intelligence, digital and sustainable solutions, prioritizing user experience and data driven services.”

He emphasized cross-border collaboration to address shared environmental challenges and broader access to technologically advanced products in short vehicle development timelines. He was joined by Xavier Roca Ramon, general director for industry at the government of Catalonia, who said, “The next few years will be decisive for the future of Europe’s industry. Sustainability challenges are an opportunity for energy and electronics manufacturers to enter the automotive sector, and for local companies to supply this new value chain. We should engage with Chinese and Korean companies as we have with American and Japanese. In an unpredictable economic climate, Catalonia offers stability by hosting key players in development, validation and integration of EV components and battery production.”

The plenary session featured Hyundai Motor Company’s president and CEO, José Munoz, who gave the principal speaker presentation on the future of mobility. Like other OEMs, Hyundai is aiming to be carbon neutral by 2045.

Mehdi Ferhan, Volvo Group’s senior vice president – powertrain engineering, participated in a panel discussion titled Managing change: OEMs and the evolution of mobility. In an on-site interview, Ferhan said that a change of mindset is needed within the company when it comes to simulation: “We are working on improving simulation confidence levels in our engineering population, taking advantage of data acquisition and knowledge. Data is the new oil. Thanks to connectivity solutions, we have the capacity with compute power and AI to better perform validation on long test profiles.”

He wouldn’t comment on the swift development cycles from Chinese OEMs, but said, “It’s great to see similarities and differences in product life cycle approaches at WMC. The commitment to sustainability and electrification are very similar.”

And when asked about the area of development and testing he feels most pressure, he said, “In my core powertrain expertise, there is pressure on pollutants and CO₂. Most tests we perform are to be compliant and ensure the organization lowers carbon emissions.”

Jin Shang, assistant president of Chery Auto and CEO and CTO of Kaiyang Laboratory, also presented a keynote on the safety and security of artificial intelligence in AI+ vehicles, including AI safety in models, training, data privacy, regulations and ethics. He encouraged building an in-depth defense system and enhancing quantum-resistant capabilities in cybersecurity, but said the big challenge is cost.

Read ATTI‘s interview with Ferhan at Volvo Group. 

Technical sessions

Within the Digitalisation and AI – model-based system engineering session, Steve Miller, a consultant who has worked for Amazon and GM, presented large language solutions for automotive SW quality improvements. He demonstrated that a two-stage prompt engineering approach can deliver high-quality code refactoring results that speed up workflows by many hours, and discussed how this could advance the field with improvements in CLI-based agentic coding.

There was also a presentation from Jose-Manuel Rodriguez-Fortun, R&D engineer at the Aragon Institute of Technology, on the XILforEV project for distributed co-simulation for designing electric vehicles and its future use for software-defined vehicles in the framework of the Code4EV project. Results were evaluated on three use cases: data-driven EV optimization, EV health monitoring and predictive maintenance, and smart motion control. Rodriguez-Fortun said the project seeks to define a toolchain for complete development and operation process and that a DevOps approach enables continuous functionality improvement (software) and deployment.

In the Artificial intelligence and automation in product development session, Dr Núria Mata, head of department at Fraunhofer IKS, presented APIKS – a modular framework for rapid prototyping and validation of automated driving systems. Integrated with the CARLA (Car Learning to Act) simulator, APIKS offers a simplified framework for small-scale vehicle integration of AD functions. Bridging academia and industry and focusing on pre-development, Fraunhofer can create corner cases and provide proof-of-concept results using heuristics and machine learning.

On automated driving development challenges, Dr Mata said ML relies on data and is often unpredictable: “Algorithms and systems need to be developed to predict real-world conditions, interpret vast amounts of data and ensure simulation covers diverse environmental conditions.”

A keynote session on the role of AI in CAE featured a panel discussion in which moderator Dr Jose Serras-Pereira, mobility advisory director at Frost & Sullivan, emphasized the need to demystify AI for engineers. Morgan Jenkins, chief product officer at Secondmind.ai, echoed this, stating, “It’s just another software tool – in CAE, AI can be ML and optimization. Engineers are inquisitive but held to account, so they need to trust the tools. Proof of concepts are great, but the real test comes in deployment. It’s about repeatability and trust.”

Exhibition highlights

The V4Safety project presented demonstrations on the effective use of simulation. Sytze Kalisvaart, StreetWise project manager at TNO, said, “Many simulation claims focus selectively on positive outcomes, but things can still go wrong. The main challenge for the industry is that regulatory bodies often don’t know how to critically assess simulation results. OEMs address these limitations through extensive real-world testing, yet they remain eager to accelerate their development cycles by improving virtual testing. It’s about more than marketing how realistic a simulation looks – high-quality rendering is most valuable, for example, when assessing safety and camera perception. You can’t compare data you don’t understand, so we help organizations choose the right simulation provider for their specific needs.”

Applus Idiada also presented its new Iris system, an AI-based automotive regulatory knowledge database for certifying products for different markets. Monthly regulatory monitoring reports give companies more time to update a product to fulfil new requirements. By receiving these updates before new regulations take effect, companies gain extra lead time to make necessary changes or improvements to their products.

Hear from FISITA’s Craig at 2:45pm at The Future of Automotive Testing Conference in Novi, Michigan, on October 22. 

Visit the Automotive Testing Expo North America website to find out more about this year’s event and to secure your attendance.

Visit the FISITA website to learn more about its work and upcoming events. 

Drive35, delivered by the Department for Business and Trade in partnership with the Advanced Propulsion Centre and Innovate UK, supports large-scale industrial transformation projects. It focuses on collaboration in software-defined vehicle development, hydrogen systems development and manufacturing scale-up – connecting late-stage R&D with industrial production.

Odosolutions contributes with its data infrastructure that captures high-frequency vehicle data and translates it into secure, real-time cloud analytics, enabling predictive maintenance, maximizing uptime and reducing risk across the electric vehicle lifecycle – from development and validation to full fleet deployment.

To reinforce local supply chains and create skilled technical jobs, Odosolutions is currently assessing UK-based assembly and test facilities for its logger family. In partnership with OEMs and Tier 1s, the company provides production-grade diagnostics and remote analytics to accelerate zero-emission and software-defined vehicle development.

Early feasibility studies and pilot manufacturing are underway to scale these solutions to industrial levels. In live trials, Odosolutions’ telemetry systems are already boosting uptime and accelerating development cycles. Features like real-time monitoring, over-the-air configurability and resilient edge logging are helping to reduce program risk and shorten validation timelines.

“Drive35 is a chance to scale zero-emission capability at pace. Our job is to make data effortless – from rugged loggers at the edge to secure cloud insight for engineers and operators – so programs move faster with less risk,” said Umesh Patel, business director at Odos.

In parallel with Drive35, the UK government has launched the Connected and Automated Mobility (CAM) Pathfinder project – a £150m (US$183m) investment designed to support the deployment of connected and autonomous vehicle systems through feasibility studies, real-world trials and system enhancements.

The CAM Pathfinder program, which supports a range of funded initiatives to speed up connected and autonomous mobility in the UK, is well matched with Odos’s CAN-to-cloud infrastructure. Projects include assessing technical, commercial and regulatory pathways for autonomous HGVs, expanding autonomous mobility trials in live environments like airports, and evaluating CAM applications across freight, public transportation and depot operations.

These projects depend on reliable, high-integrity data systems to safely operate and scale CAM technologies. Odosolutions telemetry solutions provide the low-latency CAN-to-cloud technology, cybersecure cloud integration and real-time operational intelligence required to bridge prototype testing and live fleet deployment – an increasingly important factor as CAM demonstration projects move toward commercial readiness.

As the Drive35 and CAM Pathfinder initiatives move forward, the emphasis will be on developing the infrastructure, skills and partnerships required to deliver zero-emission transportation and advanced mobility systems at scale. Odos aims to support industry, government and research organizations by providing secure, high-integrity data capabilities that accelerate innovation while minimizing risk.

Odos’s solutions are already being put to the test in high-demand environments. TAE Power recently integrated the company’s telemetry and dashboards into its pulse-charging rigs, giving engineers round-the-clock system monitoring, anomaly alerts, remote configurability and secure zero-loss datalogging. This has helped the team maintain oversight, protect critical data and expedite the testing process.

“Odos provides production-grade telemetry from day one, shortening test cycles and building confidence to scale,” said a TAE Power Solutions spokesperson.

In related news, Aurrigo has been awarded £1m to advance autonomous transportation trials across the UK

Among the records smashed was a record for the greatest distance covered by an electric vehicle in 24 hours. The technology platform traveled 5,479km (3,404 miles), surpassing the previous sub-4,000km (2,485 miles) record by 1,518km (943 miles) – a 38% increase.

The tests also included AMG’s ‘drive around the world in eight days.’ Drivers maintained a constant speed of 300km/h (186mph), stopping only to recharge at power levels averaging around 850kW. After each charging stop, the vehicle accelerated back to 300km/h (186mph) for eight consecutive days. According to analyses, the 300km/h (186mph) speed offered the optimal balance between track speed and charging stops, delivering the fastest overall time.

The Concept AMG covered the distance of 40,075km (24,901 miles) in exactly 7 days, 13 hours, 24 minutes and 7 seconds – beating the 8 day target by a wide margin. Along the way, the Concept AMG set a number of additional performance records.

Two vehicles participated in the demanding endurance challenge. After more than 7 and a half days of continuous operation, both finished just 25km (15.5 miles) apart. The program required 3,177 laps of the 12.68km (7.88 miles) Nardò circuit, where race drivers completed two‑hour shifts. On average, each vehicle drove more than 5,300km (3,293 miles) per day. Conditions were far from favorable, with daytime ambient temperatures rising up to 95°F (35°C) in the shade, climbing higher under direct sunlight on the exposed track.

“As an F1 driver, I’m used to pushing technology to its absolute limits – the Concept AMG GT XX really impressed me. The axial flux motors respond as immediately and precisely as a Formula 1 drivetrain, but with an endurance that I have only ever experienced with combustion engines. This technology will revolutionize the driving experience – both on the racetrack and on the road,” commented George Russell, Mercedes‑AMG Petronas F1 team driver.

Electric endurance

The drive system, featuring three axial flux motors and the latest high-performance battery, enabled continuous electric power and ultra-fast-charging. This allowed the vehicle to perform consistently under extreme conditions at Nardò, with the battery maintaining optimal temperatures for both high performance and rapid charging.

The axial flux motors, which are significantly more compact, lighter and about three times more power-dense than conventional electric motors, enabled high-performance driving that could be consistently and repeatedly delivered.

Three axial flux motors and a directly cooled battery concept

The concept vehicle produced over 1,000kW (>1,341hp) using three motors in high-performance drive units. Two axial flux motors on the rear axle operated continuously, while a front booster motor activated as needed for extra power or traction.

The high-performance battery is a new development from Affalterbach, inspired by Formula 1. It uses newly developed cylindrical NCMA cells, which offer efficient cooling and an energy density of over 300Wh/kg.

The battery cells were directly cooled by an electrically non-conductive oil, regulating the temperature of over 3,000 cells for even heat dissipation. This supported the battery’s high continuous power. Operating at over 800V reduced the weight with lighter cables and shortened charging times, while thermal management ensured optimal cell temperature for maximum performance under extreme conditions. The AMG charges at over 850kW across much of the charging curve. In five minutes, it can add about 400km of range (WLTP).

“With the Concept AMG GT XX technology program, we are entering a new dimension of performance – this time with fully electric drive. The goal is to redefine the limits of what is technically possible in the age of electric drives. So what could be more fitting than to chase records once again? Our mission: to redefine the very standards of performance with groundbreaking technologies and innovations. The motivation and dedication of the cross-functional team from Mercedes-AMG, Mercedes-Benz, Mercedes-Benz Mobility and our F1 engine experts at Mercedes-AMG High Performance Powertrains throughout the entire preparation phase were boundless. I am immensely proud of the unprecedented achievement of the entire team in this unique record drive,” said Markus Schäfer, member of the board of management of Mercedes‑Benz Group AG, and chief technology officer, development & purchasing.

In related news, Siemens Digital Industries Software recently announced that Nidec Corporation has adopted Teamcenter X software from the Siemens Xcelerator portfolio of industry software, with the goal of achieving innovative motor development and supply, and setting new industry standards, including automotive