Electric Vehicle (EV) Range Extender Market Size - By Component, By Range Extender, By Vehicle, By Fuel, Growth Forecast, 2025 – 2034

Electric Vehicle Range Extender Market Size

The global electric vehicle range extender market size was valued at USD 1.4 billion in 2024 and is estimated to register a CAGR of 8.5% between 2025 and 2034. The growth of the market can be attributed to the rising environmental awareness and stricter government regulations which driving global demand for EVs. Governments are implementing policies to encourage automakers to produce cleaner vehicles.
 

For instance, in October 2024, the Indian government launched the PM E-Drive subsidy scheme, offering incentives for EV purchases and supporting the construction of charging stations. With a budget of USD 442 million, the scheme aims to fund 2.5 million electric two-wheelers, 316,000 electric three-wheelers, and over 14,000 e-buses. Additionally, around USD 60 million is allocated for e-ambulances and USD 527 million for vehicle purchases. These efforts, along with growing consumer preference for eco-friendly transportation, are accelerating the shift to EVs.
 

However range anxiety, the fear of running out of battery before finding a charging station remains a challenge, especially in areas with limited infrastructure. Range extenders, which recharge the battery while driving, offer a solution by allowing longer trips without frequent charging stops. This makes EVs more appealing to long-distance travelers and consumers in rural areas. This is expected to drive the growth of EV range extender market.
 

Furthermore, range extenders bridge the gap between current battery capabilities and future improvements, allowing automakers to meet consumer needs while the charging network expands. This flexibility is crucial in markets where infrastructure expansion is growing but not yet widespread, thus driving broader EV adoption and supporting market growth.
 

The rising adoption of hydrogen fuel cell range extenders is accelerating, especially in regions investing heavily in the hydrogen economy. Governments and industries in Europe, Japan, and South Korea are developing hydrogen infrastructure development to achieve decarbonization goals. These extenders generate electricity from hydrogen, emitting only water, making them a top zero-emission solution. They offer longer ranges and faster refueling than batteries, making them ideal for commercial vehicles and areas with strong sustainability targets.
 

Electric Vehicle Range Extender Market Trends

Advancements in range extender technologies such as fuel cells and micro-turbines are significantly improving their appeal. Fuel cells use hydrogen to generate electricity, offering a zero-emission solution that supports sustainability goals. Micro-turbines, known for their small size and high efficiency, provide a lightweight and cost-effective alternative to traditional engines. These innovations reduce fuel consumption and emissions while improving the range and performance of electric vehicles. As a result, range extenders are becoming a viable option for long-distance travel and commercial use, addressing major challenges in EV adoption.
 

Furthermore, companies operating in the market are focused on launching new and enhanced range extender technology. For instance, in May 2024, HORSE, a low-emissions powertrain systems provider, launched its latest range extender technology for passenger and light commercial vehicles. The new powertrain offers a 200km pure-electric range, with an additional 600km from the engine, totaling over 800km. This innovation lets drivers travel long distances and easily access low-emission zones.
 

The high-voltage battery in this system is over 50% smaller than those in similar EVs, leading to cost savings, reduced weight, and less strain on the critical mineral supply chain. The engine powers the battery through an electric generator, providing 50kW for passenger vehicles and 80kW for light commercial vehicles.
 

Advancing battery technologies are posing a significant challenge to the EV range extender market. As battery energy densities improve, EVs can travel longer distances on a single charge, reducing the need for range extenders. Innovations such as solid-state batteries and fast-charging solutions are making batteries more efficient and cost-effective, which may make range extenders less necessary in the future.
 

Additionally, the rapid development of faster charging infrastructure allows EVs to recharge more conveniently and frequently, further decreasing reliance on range extenders. As a result, automakers and consumers are focusing more on pure electric solutions with better battery capabilities, reducing the role of range extenders in many EV models.
 

Electric Vehicle Range Extender Market Analysis

Based on vehicle, the market is divided into passenger cars and commercial vehicles. In 2024, passenger cars segment held a market share of over 65% and is expected to cross USD 1.5 billion by 2034. In many rural and suburban areas, electric vehicle charging infrastructure is still growing. Consumers in these regions face concerns about range anxiety due to the limited number of charging stations.
 

Range extenders offer a practical solution by providing extra power and extending the driving range, making electric passenger cars more practical for longer trips. Additionally, as consumers look for a balance between environmental sustainability and practical performance, many are choosing hybrid electric vehicles (HEVs). These vehicles combine battery-powered electric drivetrains with range extenders such as small internal combustion engines. This combination allows for zero-emission driving in cities and extended range for longer journeys, making HEVs an attractive option in areas with less-developed charging infrastructure.
 

Based on component, the EV range extender market is categorized into electric motors, battery packs, generators, power convertors and fuel cells. The battery packs segment held a market share of around 42% in 2024. Advancements in lithium-ion and solid-state batteries have increased energy density, allowing smaller, lighter battery packs to achieve longer ranges. These improvements help range extender systems by enabling EVs to travel further on electric power before needing the extender, enhancing efficiency and performance. Faster charging technologies, such as ultra-fast charging stations and smart infrastructure, support the use of larger battery packs in EVs, making long-distance travel easier.
 

Addtionally, innovations in sustainable and recyclable battery materials are also making larger battery packs more eco-friendly. Combining these advanced battery packs with range extenders boosts the sustainability and performance of EVs.
 

North America electric vehicle range extender market accounted for 30% of the revenue share in 2024. In North America, especially the U.S., the government is supporting EVs with consumer incentives and tax credits for automakers. Stricter emissions rules are pushing automakers to create HEVs with range extenders. This helps meet environmental standards and eases consumer worries about range.
 

Additionally, consumers in the U.S. are increasingly seeking electric vehicles with longer ranges that can compete with traditional ICE vehicles. This demand is driving the integration of range extenders to ensure that EVs remain practical for long-distance driving, particularly in rural and less densely populated areas where charging infrastructure is not as extensive.
 

Europe has presence of strict vehicle emission standards, pushing automakers to adopt hybrid technologies with range extenders to meet sustainability goals. This shift towards electrification is increasing demand for range extender-equipped vehicles, especially in commercial fleets and long-distance travel. Additionally, Europe is investing heavily in the hydrogen economy, with Germany and France leading in building hydrogen refueling infrastructure. Hydrogen-powered fuel cell range extenders offer a clean alternative to traditional fuels, making them an attractive option for zero-emission vehicles needing extended range.
 

In Asia-Pacific, countries such as China, Japan, and South Korea are heavily subsidizing electric vehicle development to combat pollution and reduce fossil fuel use. Range extenders in hybrid vehicles are promoted to improve EV viability in markets with large distances between cities and limited charging infrastructure. Furthermore, with the rapid growth of EV infrastructure in Asia-Pacific, especially in China, there is a rising adoption of electric vehicles in both personal and commercial fleets. Fleet operators are looking for ways to reduce downtime due to charging, and range extenders offer a practical solution by providing extended range and flexibility.
 

Electric Vehicle Range Extender Market Share

Mahle and AB Volvo hold a market share of around 10% in the EV range extender market. Mahle is focused on expanding its portfolio to include hydrogen fuel cell technology, crucial for the EV range extender market. The company are integrating fuel cell-based range extenders for both passenger vehicles and commercial trucks. This aligns with global trends towards zero-emission and sustainable mobility solutions, especially in areas with growing hydrogen infrastructure.
 

Volvo is investing heavily in electrification as part of its strategy to offer a range of electric and hybrid vehicles. The company is focused on adding range extenders to their hybrid models, particularly for commercial vehicles such as trucks and buses, to allow longer operational ranges without compromising on sustainability. The company aims to lead in electrifying heavy-duty vehicles with range-extender solutions, meeting the growing demand for zero-emission commercial fleets.
 

Electric Vehicle Range Extender Market Companies

Major players operating in the EV range extender industry include:

• AB Volvo
• AVL
• Ballard Power Systems
• Ceres Power
• General Motors
• Horse Powertrain
• Hyundai Mobis
• Mahle
• Schaeffler
• Valeo
   

Electric Vehicle Range Extender Industry News

• In September 2024, HORSE partnered with Brazilian EV start-up Lecar to supply its HR10 range extender engine for the Lecar 459 hybrid. Under this partnership, the company will provide 12,000 units of its 3-cylinder HR10 engine each year to Lecar. This engine, designed to run on low-emission petrol and ethanol flex fuels common in Brazil, features direct fuel injection, double overhead camshafts, and a turbocharger. HORSE manufactures these engines at its plant in Curitiba, Brazil, making it convenient to supply Lecar.
   
• In August 2024, Avatr launched Kunlun, its new range extender technology, and announced plans to launch new pure electric and range-extended electric vehicles (REEVs). The mid-sized SUV, Avatr 07, will be launched with both pure electric and range-extended options by end of 2024. Kunlun will debut in the Avatr 07, aiming to make the driving experience of REEVs similar to that of pure EVs.
   

The EV range extender market research report includes in-depth coverage of the industry with estimates & forecast in terms of revenue ($Mn) and shipment (units) from 2021 to 2034, for the following segments:

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Market, By Component

• Electric motors
• Battery packs
• Generators
• Power converters
• Fuel cells

Market, By Range Extender

• Internal Combustion Engine (ICE)
• Fuel cell
• Battery-based

Market, By Fuel

• Gasoline
• Diesel
• Hydrogen
• Alternative fuels

Market, By Vehicle

• Passenger cars
  • Sedans
  • Hatchbacks
  • SUVs
  • Others 
• Commercial vehicles
  • Light Commercial Vehicles (LCVs)
  • Heavy Commercial Vehicles (HCVs)

The above information is provided for the following regions and countries:

• North America
  • U.S.
  • Canada
• Europe
  • UK
  • Germany
  • France
  • Italy
  • Spain
  • Russia
  • Nordics
• Asia Pacific
  • China
  • India
  • Japan
  • Australia
  • South Korea
  • Southeast Asia 
• Latin America
  • Brazil
  • Mexico
  • Argentina 
• MEA
  • UAE
  • South Africa
  • Saudi Arabia