BorgWarner made a commanding statement at Busworld Europe 2025, unveiling a comprehensive suite of cutting-edge electric propulsion, thermal management, and battery technologies that promise to reshape the commercial vehicle landscape. The automotive supplier’s exhibition demonstrated how integrated solutions can transform the efficiency and performance of electric buses and commercial vehicles across the industry.
The company’s strategic showcase revealed a holistic ecosystem of interconnected technologies, from sophisticated high-voltage electric fans to advanced battery modules and fully integrated drive systems, positioning BorgWarner as a one-stop solution provider for electric commercial vehicle manufacturers.
Revolutionary Thermal Management Takes Center Stage
Among the standout innovations were BorgWarner’s next-generation high-voltage electric fans, engineered specifically for the demanding thermal requirements of buses and heavy-duty trucks. The company presented two distinct eFan solutions: a compact 3-5 kilowatt unit tailored for standard bus applications, featuring air-cooled power electronics seamlessly integrated into the rear housing, and a more robust scalable system delivering 10-20 kilowatts for heavy-duty applications spanning 12.5 to 18.5-meter vehicles.
The thermal management portfolio extends far beyond cooling, encompassing sophisticated high-voltage air and coolant heating systems designed to optimize both cabin comfort and battery performance. These innovative heaters rapidly elevate cabin temperatures while simultaneously supporting battery efficiency – a critical factor in cold-weather operation. Many of these breakthrough solutions have already proven their worth in passenger vehicle applications and are now being adapted for commercial vehicle deployment, including enhanced 24-volt variants specifically engineered for the demanding requirements of bus operations.
BorgWarner’s engineering team also demonstrated their innovative inter-cell e-coolers, featuring a distinctive “snake form” design that maintains optimal operating temperatures for high-performance cylindrical battery cells. These sophisticated cooling modules accommodate both cylindrical and prismatic cell configurations, ensuring maximum efficiency and extended battery life.
Next-Generation Battery Technology Redefines Industry Standards
The battery solutions showcase proved to be a major highlight, with Dr. Martin Busche, who leads R&D, product strategy and business development for battery systems, providing insights into the company’s impressive track record. BorgWarner’s NMC (nickel manganese cobalt) cylindrical 21700-cell-based battery packs have been successfully operating in production environments since 2021, with each sophisticated pack accommodating up to 9 modules (9 AKM) that integrate 600 cells with advanced liquid cooling, comprehensive cell-level fusing, precise voltage monitoring, and intelligent thermal management systems.
“We have deployed almost six gigawatt-hours of NMC battery capacity, equivalent to 60,000 packs annually across Europe and the US,” Dr. Busche revealed, highlighting the impressive scale of deployment. These modules distinguish themselves through exceptional energy density, multiple layers of safety protection, and warranties extending beyond 10 years, creating a compelling value proposition against competing global offerings.
The company is simultaneously advancing its Generation 3.3 NMC modules, which deliver a substantial 5% improvement in energy density alongside updated hardware and software architectures. These advanced modules comply with rigorous functional safety standards (FUSA up to ASIL Level C), comprehensive cyber security protocols, EU battery regulations, and ASPICE Level 1 requirements. The emphasis on modularity and flexibility enables pack configurations ranging from 5 to 9 AKM, accommodating buses of various sizes and specialized applications, including emerging first-generation autonomous vehicles.
Complementing the NMC systems, BorgWarner introduced its groundbreaking LFP blade-based battery family, specifically engineered for fully electric, “born electric” bus designs. This comprehensive range includes flat packs, compact packs, and high packs, offering impressive capacities spanning 50 to 100 kilowatt-hours with voltages reaching up to 666 volts in 1S or 2S (2 packs in serial) configurations. The flexible design philosophy allows OEMs to create optimal installations for underfloor, rooftop, or engine-compartment placements, while flat and compact packs can be connected in series to achieve 1,000 volts in 3S configuration for megawatt charging capabilities.
All battery modules incorporate BorgWarner’s proprietary software, developed entirely in-house, enabling automatic updates, cloud-based testing, and potential over-the-air (OTA) updates. The company’s commitment to standardization and modularization includes software updates delivered every two weeks with periodic major releases, ensuring future-ready products and continuous improvements without operational disruption.
Integrated Propulsion Systems Deliver Unprecedented Efficiency
BorgWarner’s integrated drive modules represent another significant technological leap, combining high-efficiency motors with advanced inverters in remarkably compact housing units. These systems, manufactured in Portugal, are currently deployed with leading European bus manufacturers and deliver impressive peak power ratings reaching 425 kW. Specialized integrated solutions are available under the Cascadia Motion brand for niche and low-volume applications.
The versatile drive modules demonstrate compatibility with both high- and medium-voltage systems, providing OEMs with flexibility to deploy identical solutions across different bus sizes and configurations. BorgWarner’s solution architects emphasized the inherent modularity and scalability of these products, ensuring seamless compatibility across multiple platforms and diverse vehicle types.
Service-First Design Philosophy Revolutionizes Maintenance
A defining characteristic of BorgWarner’s battery solutions is their exceptional serviceability. The innovative Removable Contactor Box (RCB) enables technicians to replace electronic components quickly and safely without requiring specialized high-voltage training or extensive testing procedures. This practical approach has been successfully extended to the entire LFP family, demonstrating the company’s unwavering commitment to delivering field-friendly solutions that benefit both OEMs and fleet operators.
BorgWarner’s commanding presence at Busworld 2025 reinforced its position as an undisputed leader in electric mobility, thermal management, and battery integration for buses and commercial vehicles. By delivering scalable, modular, and highly efficient solutions, the company provides OEMs with unprecedented flexibility to optimize energy storage, propulsion systems, and passenger comfort.
From advanced high-voltage eFans and sophisticated heating systems to cutting-edge NMC and LFP battery modules, plus integrated drive systems, BorgWarner is strategically positioning itself as the technology leader capable of delivering uncompromising safety, efficiency, and serviceability at competitive price points. This comprehensive approach ensures the company is perfectly positioned to meet the rapidly evolving demands of global electric bus markets while setting new industry standards for innovation and reliability.