From its headquarters in Palencia, Spain, Mahle SmartBike Systems operates as part of the Stuttgart-based Mahle Group, a global technology leader in automotive components employing more than 67,000 people worldwide. This link provides access to automotive grade development processes in electronics, lightweight construction, validation protocols and power electronics, translating into reliability, industrial scalability and repeatable quality for the e-bike industry.
The company’s philosophy ‘Light. Sport. Smart.’ guides development across both hub and mid drive platforms, ensuring that performance improvements remain aligned with integration, weight optimisation and intelligent system control.
Rear hubs
Mahle SmartBike Systems differentiates clearly between rear hub systems and mid drive platforms, addressing distinct rider profiles and OEM strategies.
The X Series hub drives, including the X20, X30, X35 and XS, are designed for road, gravel and urban applications where discretion, low system weight and seamless frame integration are essential. Within the range, motor unit weight starts at around 1.4 kg for the X20 and extends to around 1.9 kg for the X30, with each system tuned for specific bike concepts and usage targets. The X Series prioritises efficiency and a natural riding feel, delivering smooth, consistent assistance across both low and high cadences.
Sensing and tuning
A key differentiator lies in how brands can define the ride character through sensing and tuning. Depending on the system selected and OEM requirements, an X Series build can use torque-based sensing or cadence-based PAS configurations, allowing manufacturers to shape how assistance responds to rider input. On top of that, Mahle supports production level tuning so OEMs can adjust support curves, responsiveness and the overall ‘feel’ to match their model positioning. Even when using similar core hardware, behaviour can differ significantly from one brand to another, which aligns with Mahle’s platform approach.
Over the years, the X Series has powered models from reputable brands such as 3T, Bianchi, Cannondale, Orbea and Merida, supporting hundreds of models worldwide.
X ecosystem
Beyond the motor unit, the X ecosystem includes the eX1 external battery, Duo Remote, Trio Remote, Pulsar One display, e shifters, Energy Hub charger and Gateway, giving riders a complete set of options for control, display, charging and range extension across everyday use and longer rides.
All components are developed within a unified ecosystem logic, supporting cross compatibility across both X and M platforms and simplifying portfolio expansion for OEM partners. Continuous firmware updates further enhance performance, system management and connectivity features over time, supporting both existing customers and future OEM integrations.
M40 mid drive system
With the M40, Mahle openly enters the full power mid drive segment while maintaining its core integration philosophy. Developed for e-MTBs the M40 delivers up to 105 Nm of torque and 850 W peak power, with an assistance ratio of up to 600%.
Weighing 2.5 kg for the motor unit, and close to 5 kg for a complete system with the iM5 battery, the M40 positions itself among the lightest solutions in the full power category while maintaining competitive output levels. The 48V system architecture supports two battery options:
- iM5 (534 Wh), prioritising lightweight configurations and agile bike concepts
- iM8 (800 Wh), offering extended range for more demanding applications
Multi sensor control system
At the core of the M40 lies a multi sensor control system. A high-resolution wheel speed sensor (84 pulses per revolution), integrated torque sensing within the motor axle, combined with gyroscope and accelerometer inputs, enable precise and responsive motor control.
This sensor foundation supports features such as:
- Auto Hold, preventing rollback on steep inclines
- Dynamic Overrun, extending assistance momentarily after pedalling to maintain flow and control
As with the X Series, assistance behaviour can be defined by the bike brand. Production level tuning allows manufacturers to set their own support curves and responsiveness, helping them differentiate ride feel and positioning across their lineup. This configurability is central to Mahle’s OEM strategy: the system acts as a platform rather than a single fixed ride character.
From hub expertise to mid drive platform
Mahle SmartBike Systems has taken the same design priorities from its hub drives into the M40 mid drive: integration first, low system weight, and software led control that feels natural on the bike.
For OEMs, the benefit is a platform approach rather than a one size setting. Brands can tune assistance behaviour at production level, while working within an ecosystem that is built to scale across segments.
In practical terms, that means:
- Automotive grade development and validation processes
- A modular architecture that supports different bike concepts
- Production level tuning and a shared ecosystem to simplify integration and future updates
This article is sponsored by Mahle.
