BorgWarner 800-Volt iDM Secures North American OEM Contract for REEV Trucks

On February 11, BorgWarner confirmed that its BorgWarner 800-Volt iDM has been awarded a supply contract by a leading North American OEM for an upcoming lineup of range extended electric vehicle (REEV) trucks and large SUV models. The scope of supply includes a secondary integrated drive module (iDM) together with a generator module incorporating a dual inverter system. Manufacturing for the selected vehicle programs is planned to start in 2029, further strengthening the company’s footprint in advanced high-voltage electrified propulsion systems across North America.

BorgWarner 800-Volt iDM for REEV Platforms

The BorgWarner 800-Volt iDM is developed as a scalable two-in-one secondary integrated drive module integrating a high-efficiency induction e-machine with a transmission gearbox in a compact assembly. Designed to support both hybridized and fully electrified architectures, this 800V electric drivetrain solution delivers elevated power density while improving overall system-level efficiency. Its modular configuration enables deployment across multiple vehicle segments, particularly REEV trucks and full-size SUVs that demand extended driving range and high towing capability.

Compact Induction e-Machine Architecture

A defining feature of the BorgWarner 800-Volt iDM is its high torque-density induction e-machine, engineered to operate without permanent magnets. Eliminating rare-earth magnet dependence enhances supply chain robustness and aligns with long-term material sustainability strategies amid volatile raw material availability. The tightly integrated motor and gearbox arrangement also optimizes packaging efficiency, an essential requirement for range extended electric vehicle platforms where space allocation must accommodate both electrified components and internal combustion engine systems.

Dual Inverter Generator Module with Advanced Power Electronics

In addition to the secondary integrated drive module, BorgWarner will provide a generator module comprising a permanent magnet electric machine and a dual inverter generator module directly coupled to the internal combustion engine (ICE). This architecture enables efficient onboard electricity generation, extending operational range for REEV trucks and hybrid SUV platforms while maintaining consistent performance under high-load operating scenarios.

Viper Power Switch Technology Integration

The dual inverter configuration is built on BorgWarner’s advanced Viper power switch technology platform, engineered to enhance switching characteristics and thermal management performance. By optimizing inverter topology and improving power conversion efficiency, the system supports superior drivetrain responsiveness and long-term durability. Integrating high-performance power electronics within a space-efficient layout was a critical factor in satisfying the OEM’s demanding packaging, efficiency, and reliability targets.
Key technical highlights of the awarded system include:

• 800V electric drivetrain architecture enabling higher efficiency and accelerated energy transfer

• Induction e-machine design eliminating permanent magnet reliance within the iDM

• Dual inverter generator module mechanically integrated with the ICE for effective range extension

• Scalable system architecture adaptable to REEV trucks and large SUV platforms

Winning this program reflects the accelerating industry transition toward high-voltage electrified propulsion, particularly in larger vehicle segments where optimizing performance, packaging constraints, and extended range remains technically complex. With production targeted for 2029, the BorgWarner 800-Volt iDM combined with its dedicated generator module supports the next wave of electrified truck and SUV development in the North American market.