FEV, an engineering company based in Aachen, Germany, says its internal analysis suggests that using a range-extender architecture on electric trucks could reduce total cost of ownership (TCO) compared with diesel, while also lowering CO₂ emissions.
In results published in February 2026 as part of an internal research programme, FEV says the TCO impact depends on duty cycle. In short-distance operations, the company estimates savings of up to 33% compared with a conventional diesel truck. In the most unfavourable long-haul scenario, FEV estimates the TCO reduction remains around 14%.
According to the analysis, the calculations assume a “realistic European usage profile” with overnight depot charging at industrial electricity prices of around €0.19 per kWh. FEV adds that in regions with lower electricity costs, the economic advantage would be higher.
“No need to wait for megawatt charging,” FEV argues
Depending on the driving cycle, TCO for range-extender trucks can be reduced by up to 33 per cent. Source: FEV
A central element of FEV’s argument is that a range-extender setup allows operators to reduce the battery size compared with a purely battery-electric long-haul truck.
FEV says a “typical” long-haul battery-electric truck would require around 560 kWh of battery capacity, while a range-extender electric truck could manage with around 280 kWh. The company adds that even with slower AC charging at 22 kW, around 240 kWh could be recharged overnight, which it says can be enough to power the vehicle “almost entirely electrically” the next day, depending on the application.
This, FEV argues, means economical operation is possible without relying on a megawatt charging infrastructure.
“Our analysis clearly shows that the range extender makes electric trucks immediately economically and ecologically viable – without waiting for the widespread expansion of high-performance charging infrastructure,” said Dr Norbert W. Alt, COO of the FEV Group.
Why FEV says the economics work
FEV lists several reasons why it believes the range-extender concept improves cost performance:
- Smaller battery: lower vehicle cost and weight, and higher payload.
- High share of electric driving: lower energy costs, especially with overnight depot charging at industrial rates.
- Lower reliance on public high-power charging: easier integration into existing depot structures, higher operational flexibility and reduced investment risk for fleet operators.
In the long-haul scenario, FEV says the combination of lower investment costs, low operating costs and “high practicality” results in a TCO advantage of about 14% versus diesel. In short-distance mode, it says, the advantage rises to 33%.
FEV also claims a substantial climate impact. Depending on the application profile and energy mix, the company says the global warming potential could be reduced by up to 82% compared with conventional diesel trucks.
FEV says it is now focusing on commercial vehicles and long-distance transport, where it believes the technology’s “economic strengths are particularly evident”. The company adds that it is working on demonstrator vehicles to validate its analysis results in practice and translate them into marketable solutions with customers and partners.
