The automotive industry faces the challenge of bringing innovative powertrain concepts to market within increasingly shorter cycles. With the MAHLE Vehicle Development Center (VDC), we enable our customers to develop their concepts under precisely defined laboratory conditions—from virtual simulations and predictive modeling to real-world prototype testing under actual driving conditions.
For vehicles with internal combustion engines, emissions testing under WLTP (Worldwide Harmonized Light Vehicles Test Procedure) and RDE (Real Driving Emissions) is a crucial step for type approval. At the VDC, the entire WLTP test cycle can be replicated on an all-wheel-drive chassis dynamometer. To ensure standardized conditions, the test bench is designed as a climate chamber. This setup allows for precise adjustments of altitude—up to 5,000 meters—and ambient temperatures ranging from -40°C to +60°C, with the ability to dynamically vary these conditions during a programmed test run. Coupled with wind and humidity simulation, MAHLE can replicate virtually any driving scenario from around the world.
For real-world validation, we use portable emissions measurement systems (PEMS) on two designated RDE test routes to compare laboratory results with actual on-road performance.
The VDC is also equipped with a dedicated test facility for the development and validation of next-generation electric and hydrogen powertrains under similarly extreme climate conditions. Given the unique challenges of hydrogen technology, this test chamber is designed with the highest safety standards, featuring explosion-proof walls, a reinforced safety ceiling, gas sensors, and a secure gas extraction system. One of the key advantages of our adjacent but separate test chambers is that they allow parallel development while sharing certain infrastructure elements, optimizing efficiency without compromising safety.
“The industry is accelerating the development of new vehicle generations to achieve CO₂-neutral transport solutions. This is driving an increasing demand for advanced testing facilities,” says Simon Reader, Managing Director of MAHLE Powertrain. “We are proud to offer state-of-the-art testing solutions with an unparalleled range of technologies under one roof.”
MAHLE’s holistic approach, from virtual development and simulation tools to real-world testing under controlled conditions, helps automakers and engineers reduce both development time and costs.
Fewer prototypes and fewer driven test miles also contribute to a lower carbon footprint, supporting the automotive industry’s journey toward climate neutrality.