just 25 kilograms while still delivering 120 kW and 3,400 Nm.
AI-based control models will enhance power utilization by
thermal management and real-time monitoring.
High-Efficiency EDU: Chasing the 94 % Benchmark
Where the high-speed EDU focuses on compactness, the
high-efficiency EDU maximizes energy efficiency. It combines
two permanent magnet synchronous motors (PMSM) with an
intelligent clutch strategy. For typical urban driving, one motor
remains inactive, switching on only when extra performance is
needed.
This architecture delivers exceptional results: over the WLTC
cycle, the EDU achieves more than 94 % average efficiency. In
the Chinese CLTC cycle, AVL has demonstrated 94.4 % based
on vehicle measurements. In real-world terms, this translates
to energy consumption below 10 kWh per 100 km – a level
that directly extends vehicle range and reduces charging
demand.
Built-In Sustainability: Materials and Recycling
AVL’s EDU designs also address sustainability beyond the use
phase. Integrating recycled raw materials reduces lifecycle
CO2e emissions by more than 75 %. But as long as reliable
supply chains for recycled materials like copper, aluminum,
and steel are still lacking, reducing the carbon footprint can
also be achieved by choosing where the materials are pro-
duced. For instance, a ton of steel from Spain results in about
43 % fewer CO2 emissions than a ton of steel from India.
Technology choices reinforce these gains. Moving to 800 V
architectures reduces copper demand while enabling faster
charging. Additive copper manufacturing, resin-free winding
designs, and a modular system architecture cut electrical loss-
es and make disassembly and recycling easier at end of life.
The Business Case for OEMs
AVL’s EDU concepts create value across three dimensions:
• Cost: reduced material use and higher energy efficiency
lower both production and operating costs.
• Range and Performance: efficiency above 94 % enables
real-world energy savings, while high-speed architectures
deliver compact, powerful packages.
• Compliance: Design-to-CO2e supports transparent product
carbon footprints and prepares OEMs for upcoming regula-
tory product passports.
In short, the combination of high-speed and high-efficiency
EDU enables OEMs to meet customer expectations while stay-
ing ahead of regulatory and economic pressures.
Shaping the Next Generation
AVL is already developing the next generation of highly inte-
grated EDU systems, particularly suited for smaller vehicle
segments. Demonstrators have proven scalability across
platforms, supported by a modular architecture that adapts to
different vehicle segments. The direction is clear: with innova-
tive drive concepts, lifecycle sustainability, and a sharp focus
on cost and efficiency, AVL is helping make e-mobility more
attractive, affordable, and future-proof.
What Is Design-to-CO2e?
Design-to-CO2e is a development approach that
integrates carbon dioxide equivalent (CO2e) emissions
as a metric into every stage of the product lifecycle.
Rather than treating sustainability as an afterthought,
CO2e is managed as a performance metric on par with
function, quality, and cost.
Key principles include:
• From concept to disposal – considering CO2e
alongside function and cost.
• Material choice – preference for low-impact or
recycled resources.
• Manufacturing – energy- and resource-efficient
processes.
• Efficiency in use – minimizing energy consumption
during operation.
• End of life – designs that enable recycling and reuse.
By applying these principles, OEMs can reduce emis-
sions, secure critical resources, and turn sustainability
into a measurable competitive advantage.
2025