MAHLE SmartBike Systems

MAHLE has long been a tier-1 leader in the automotive industry, with their parts, such as filters and thermal management components, appearing on a wide range of OE vehicles, from VW to Toyota. During Taichung Bike Week 2025, we met up with their Ebike Drive Systems Team at The Tempus Hotel to learn more about their dealings and outlook.

The MAHLE e-bike department has been working hard to form partnerships and drive the industry forward. Formed as a result of the company's 2018 acquisition of Spanish company ebikemotion, MAHLE was given a foundation in lightweight drive systems, batteries, and connectivity.

Since then, the brand has made significant investments in R&D and increased production capacity in Spain, with the goal of establishing itself as a long-term player in the e-bike sector. MAHLE's initial offerings were compact hub motors for road and urban bikes, but in recent years, the company has expanded into more powerful segments, most recently announcing the M40 mid-drive unit for e-MTB and trekking applications.

The company strategizes on making lightweight, integrated systems that retain a bike's natural appearance and ride feel, combined with a modular ecosystem of motors, batteries, range extenders, displays, and software. Edoardo Ferraresi, Commercial Sales Lead, says they “work closely with OEM brands to customize motor behavior, assist levels, and system integration for each bike's specific application.”

Their focus on modularity, brand customization, and lightweight design gives it a distinct identity compared to “bigger” rivals. Their continued investment indicates that the company views SmartBike Systems as a long-term growth opportunity.

Partnerships Prove Clutch

Partnerships are central to MAHLE's strategy. The company has already collaborated with over 60 e-bike brands worldwide, including Bianchi, Scott, Merida, Cannondale, Orbea, Konrad, and Stevens. Technical collaborations include integration with Pinion and their Smart.Shift gearbox, sustainable frame projects with Cyclik, and aftermarket support via distributors like the UK’s ZyroFisher.

MAHLE’s e-bike lineup is both compact and straightforward. Alan Zhang, Asia Regional Sales Manager, said that MAHLE wants customers from Asia and Europe to test and "experience the beauty of the M40" now that it has entered the market. With Taichung Bike Week providing the perfect platform for hands-on testing and visualization.

With MAHLE's excitement about the M40's potential success, having key new launch partners is critical. They rely on their strong marketing and collaborators, which include Pard Design, Titan Racing, Labyrinth, Sants, and Abums—a diverse range of off-road e-bike options. MAHLE has “4 to 5 more partners in the works, with some tier 2 brands and even larger ones aimed for for 2027 and 2028,” with some already closing their specs—it just "takes some time to finalize,” said Mr. Ferraresi.

M40 Mid-Drive Motor

The M40, available now, weighs 2.5 kilograms, available with two battery options the “iM5” and “iM8” for different range requirements (the total system weighs just 5kg with the iM5 battery), and produces 105 Nm of torque and 850 W of peak power, and the iM8 can offer a range of 150km or 2500m of climbing, making it a new top choice in the market. MAHLE says it provides control and efficiency in challenging conditions and is compatible with the MAHLE ecosystem, which includes new batteries, controllers, and displays. This launch marks the start of the M series, which will continue to expand to complement the current X series of hub drives.

The sleek and discreet M40 Mid Motor (Pic: MAHLE SmartBike Systems)

Designed for off-road use, it can particularly handle dirt well. (Pic: MAHLE SmartBike Systems)

"Thanks to state-of-the-art technologies, precision engineering, and intelligent connectivity, the M40 sets new standards in the category of full-power mid-motors," says MAHLE. “With the M40 system, MAHLE SmartBike Systems is reaffirming its claim to continue driving the development of the eBike industry in the mountain bike segment.”

The M40, designed for electrified mountain and trekking bikes, provides e-bikers with powerful yet natural support that adapts to various riding conditions. Its balanced performance also makes it suitable for urban use, offering versatility across different contexts.

The M40 promises great rides for off-roading. (Pic: MAHLE SmartBike Systems)

The drive system is compatible with the ETOR crank standard and therefore ensures simple integration into a wide range of cranksets available on the market. The motor is decoupled from the frame via the MAHLE Decoupling Mounting System (DMS) in order to reduce the transmission of vibrations into the frame.

The M40 system broken down. (Pic: MAHLE SmartBike Systems)

The M40 system is intended to provide a “powerful and natural riding experience, with strong, controlled support that adapts to changing conditions.” It provides “smooth power delivery even at high cadences, enhancing rider control, especially on technical trails and climbs.”

The system features advanced sensors that ensure maximum responsiveness, as well as ultra-precise speed sensors that maintain a smooth motor response while avoiding jerky movements. It dynamically adjusts assistance based on riding data while detecting speed changes with remarkable accuracy. Motor Dynamic Overrun ensures smooth transitions, while Hill Brake with "Auto Hold” prevents rollback on inclines. The system reduces energy consumption by utilizing compact and lightweight MAHLE 48V batteries.

The rear wheel speed sensor provides precise measurements. (Pic: MAHLE SmartBike Systems)

The components include the iM5 (534 Wh), or iM8 (800 Wh) for shorter, or extended ventures. (Pic: MAHLE SmartBike Systems)]

(Credit: MAHLE SmartBike Systems)

Busy Times In Hard Times

Despite the lower attendance at Taichung Bike Week 2025, MAHLE SmartBike Systems informed us that they were fully booked with numerous meetings. Many customers came seeking new opportunities, particularly with their new mid-drive, the MAHLE M40.

It's a "steady and niche market, particularly for high-end lightweight solutions, and many customers have already committed to making extensive use of the M40 motor in 2026, with the following year with even more picking it up,” said Mr. Ferraresi.

MAHLE, without disclosing names, suggested they had lots of ongoing discussions about new partners. While many other companies were checking out of their hotel rooms and many employees were leaving for the airport, MAHLE had customer visits until 3 p.m. on the final day.

Edoardo Ferraresi and Alan Zhang had a busy week but were welcoming and showed off the M40 in an example frame at The Tempus Hotel. (Pic: Ash Suter)

The M40 had been the primary focus of TBW. But how will they continue to improve and stand out? Mr. Zhang says that they "stay one step ahead of the game for their customers.” They take great pride in their IoT (Internet of Things) integration progress, but progress can be relative. "Of course there's always room for improvement, but our M40 is already really powerful in regard to torque performance, the top 2 or 3 for sure," he said.

Wandering the booths and investigating the signage at Taichung Bike Week, you'd be forgiven for thinking Black Friday or the January Sales had arrived early, with many brands slashing prices on current lines or even looking to replace current ranges with a new, cheaper variant.

However, MAHLE has not felt the need to discontinue any of their product lines or lower their prices. They introduced the X30 just last year, and while the X20 was a candidate for price reduction, it instead had a torque upgrade from 55 Nm to 65 Nm and a power increase from 250 W to 275 W, both being firmware upgrades on the same 1.4 kg motor, and new units support the Universal Derailleur Hanger standard for better shifting and durability.

As of August 2025 the new X20s come ready with upgrades. MAHLE will reach out to their community on how current X20 users can receive enhancements through upcoming firmware updates later in 2025, offering riders more choices for their riding experience while adhering to their ‘Light. Sport. Smart.’ philosophy.

Strong partnerships are key to MAHLE’s success; their partners know just how stable MAHLE products are: “The value is there in the aftermarket for us,” said Mr. Ferraresi. So no need to hit the panic buttons yet. MAHLE’s X-series motors are currently used by brands such as Ridley, Scott, Wilier Triestina, Bianchi, Merida, Cannondale, Orbea, and Van Rysel.

It takes “years of development,” with 3 years already invested into the M40, with constant hardware improvements and changes—but also the firmware needs careful attention. Such work contributed to providing the X20’s upgrade package. Since June alone they’ve updated the firmware two times, with November bringing even further fine-tuning and upgrades. The app development allows the units to adapt to new systems and ensures user interfaces remain intact.

The X20, aimed at high-end riders, has just had some upgrades. (Pic: MAHLE SmartBike Systems)

The X30 targets more casual riders who still expect great performance. (Pic: MAHLE SmartBike Systems)

Service and Support

With so many players in the motor sector, how can MAHLE stand out? By “pushing on the side of natural power, low care, and support,” Mr. Ferraresi said.

MAHLE deals with many subpartners around Europe, the UK, the US, and Australia, providing a spread-out service platform. They have a European call center and deal with many things internally. They also have an active claims service for customers. One key partner is Specialized, whom they've been serving for six years, so they have a lot of experience and are confident in their model.

MAHLE Lifecycle and Mobility is establishing a Global Training Center in Stuttgart, spanning over 1,300 sqm with five workstations and capacity for 15 partners, aimed at providing advanced training for its e-bike and automotive departments. This initiative will also expand to France and Italy.

Additionally, MAHLE has launched an online training portal that offers a diverse range of courses, including free live online sessions, short e-learning modules, and easy booking for in-person training. The portal contains over 120 technical documents available in multiple languages, including German, English, Polish, and Portuguese, with plans for further expansion.

MAHLE also recently announced the 2025 edition of its Smart Trainings Program. From October, 70 in-person sessions are planned across Europe. The program aims to enhance dealers' technical knowledge of the M40 System and other X Series systems (X20, X30, XS, X35).

It helps partners achieve Certified Partner PRO status, offering benefits such as premium visibility in the MAHLE Dealer Locator, early access to product launches, and exclusive marketing and technical resources.

This certification ensures that shops can effectively support MAHLE-equipped eBikes. Registration is open for dealers in several European countries, including Italy, Austria, Spain, France, Germany, Switzerland, Portugal, Belgium, the Netherlands, and the United Kingdom. You can register here