FORVIA HELLA Secures Major Series Orders for Highly Integrated EnergyCore Solutions
International automotive supplier FORVIA HELLA has secured two major series production orders for its highly integrated EnergyCore solutions, marking a significant step in the company’s expansion of its battery and power electronics portfolio. The orders cover the company’s first 3-in-1 high-voltage battery management system and a 48-volt PowerPack that combines battery technology with power electronics in a single integrated product.
The new contracts strengthen FORVIA HELLA’s position in the automotive electrification market and support FORVIA Group’s IGNITE strategy, which focuses on expanding the company’s capabilities from supplying individual battery and power electronics components to delivering integrated system solutions. These technologies are designed to reduce vehicle costs and complexity while minimizing weight, installation space and the number of components required.
The two systems will be supplied to separate international automotive manufacturers operating in the Americas and Europe. The combined order volume is in the mid-three-digit million-euro range. Series production is scheduled to begin in December 2027 and spring 2028, respectively.
In addition to these new contracts, FORVIA HELLA has previously been selected to develop and manufacture a 12-volt lithium-ion battery pack in China. Together, these developments demonstrate the company’s continued efforts to expand its product portfolio and strengthen its role in the transition toward more affordable and efficient vehicle electrification.
Major Orders Strengthen FORVIA HELLA’s EnergyCore Portfolio
The latest series orders represent an important milestone in FORVIA HELLA’s strategy to develop highly integrated battery and power electronics solutions for different vehicle architectures. As automotive manufacturers seek to improve energy efficiency, reduce production costs and simplify vehicle systems, integrated technologies are becoming increasingly important across hybrid and electric vehicle platforms.
By combining multiple functions within a single system, FORVIA HELLA aims to reduce the number of individual components and interfaces required in vehicles. This approach can simplify vehicle architecture, reduce wiring requirements and improve the use of available installation space. It can also help manufacturers address increasing demands for functional safety and efficient energy management.
Prof. Dr. Peter Laier, CEO of FORVIA HELLA, highlighted the strategic importance of the new contracts and their role in advancing the company’s technology portfolio.
“For us, these new series orders represent both a significant expansion of our portfolio as well as an important validation of FORVIA Group’s IGNITE strategy. They demonstrate that customers increasingly value highly integrated system solutions that reduce complexity while maintaining the flexibility needed to address different vehicle architectures and requirements. With our EnergyCore portfolio, we are combining our strong expertise in battery and power electronics into scalable system solutions that create clear value for automotive manufacturers.”
The orders reflect growing interest in technologies that combine multiple electronic and battery management functions in compact, scalable systems. Through its EnergyCore portfolio, FORVIA HELLA is working to meet these requirements while providing automotive manufacturers with solutions that can be adapted to different platform designs and electrification strategies.
3-in-1 High-Voltage Battery Management System Introduces Integrated Architecture
One of the two new contracts covers FORVIA HELLA’s first 3-in-1 high-voltage battery management system. The technology integrates three essential components into a single system architecture: the Battery Management Unit (BMU), Cell Measurement Units (CMUs) and Battery Junction Box (BJB).
These components traditionally perform separate but interconnected functions within a battery system. By bringing them together in one highly integrated solution, FORVIA HELLA aims to simplify system architecture and improve coordination between battery monitoring, management and high-voltage power distribution functions.
The 3-in-1 system is among the first solutions to combine the functions of the BMU, CMU and BJB within a single unit. This integrated configuration enables direct control of high-voltage current flow between the battery and the vehicle, supporting faster system responses and improved functional safety.
Another important feature is its optimized cell monitoring architecture. The system is designed to reduce the number of Cell Measurement Units required for battery monitoring. Fewer units can translate into a reduction in components, wiring requirements, installation space and overall system weight. These improvements also contribute to lower system costs, providing potential benefits for automotive manufacturers seeking to make electrified vehicles more affordable.
The initial design of the 3-in-1 battery management system targets the requirements of larger full-hybrid vehicles. However, its scalable architecture allows the technology to be adapted to different original equipment manufacturer (OEM) requirements and battery pack configurations.
The underlying concept can also be applied to fully electric vehicles, creating opportunities for the technology to support a broader range of electrified vehicle platforms in the future.
By integrating critical battery management and power distribution functions, FORVIA HELLA aims to help manufacturers simplify high-voltage system design while maintaining the performance, flexibility and safety requirements of modern vehicle architectures.
48-Volt PowerPack Combines Battery Management and Power Electronics
The second series order covers FORVIA HELLA’s 48-volt PowerPack, an integrated solution that combines a low-voltage DC/DC converter with a low-voltage battery management system.
The integration of these functions into one product is intended to reduce system complexity, lower costs and decrease the number of components required within a vehicle. By consolidating key electrical functions, the PowerPack can help automotive manufacturers simplify vehicle architecture and make more efficient use of available space.
The 48-volt PowerPack is designed for hybrid vehicles and is installed alongside the conventional 12-volt battery. It supports important energy management functions, including energy recuperation and coasting with the combustion engine switched off.
Energy recuperation allows vehicles to recover energy that would otherwise be lost during certain driving conditions and use it to support electrical systems. Coasting with the combustion engine switched off can also contribute to improved energy efficiency, depending on the vehicle’s operating conditions and system configuration.
A central focus of the series development was meeting the demanding functional safety requirements associated with future premium vehicle platforms. As vehicles incorporate increasingly sophisticated electrical and electronic architectures, reliable energy management and safety-oriented system design remain essential considerations for automotive manufacturers.
The integrated PowerPack is intended to address these requirements while offering a compact solution that combines battery management and power conversion capabilities.
Expanding Integrated Electronics Capabilities
Jörg Weisgerber, Member of the Management Board responsible for the overall Electronics business at FORVIA HELLA, emphasized the company’s experience in battery and power electronics and its commitment to expanding beyond individual component supply.
“For over 20 years, our customers have valued us as a reliable and technologically leading component supplier in the field of battery and power electronics. Building on this foundation, we are consistently expanding our portfolio. We deliver integrated solutions that reduce system complexity and the number of interfaces in the vehicle, while also lowering weight, space requirements and costs. Above all, we are making a significant contribution to actively shaping the transition toward affordable electrification.”
The company’s established expertise in battery and power electronics provides a foundation for developing integrated systems that address the evolving requirements of hybrid and electric vehicles. By combining functions into scalable products, FORVIA HELLA aims to help manufacturers reduce the complexity associated with vehicle electrification while improving packaging efficiency and cost competitiveness.
The new orders also support the company’s broader ambition to strengthen its position as a provider of complete system solutions rather than individual electronic components. This strategy is aligned with the automotive industry’s continuing focus on modular architectures, efficient power management and cost-effective electrification technologies.
Supporting the Transition Toward Affordable Electrification
FORVIA HELLA’s latest EnergyCore orders highlight the growing importance of system integration in the development of modern vehicle electrical architectures. The 3-in-1 high-voltage battery management system and 48-volt PowerPack address different requirements across hybrid and electric vehicle applications, while sharing a common objective of simplifying system design and reducing costs.
With a combined order volume in the mid-three-digit million-euro range, the contracts represent a significant commercial achievement for the company. Production is expected to begin in December 2027 and spring 2028, supporting the introduction of the technologies into vehicles produced by automotive manufacturers in the Americas and Europe.
The previously awarded 12-volt lithium-ion battery pack programme in China further illustrates FORVIA HELLA’s efforts to expand its battery technology capabilities across international markets.
As automotive manufacturers continue to develop electrified vehicle platforms, demand for compact, efficient and scalable battery and power electronics solutions is expected to remain an important factor in product development. Integrated technologies can help address challenges related to component count, wiring, packaging, weight and manufacturing costs.
Through its EnergyCore portfolio and the latest series production orders, FORVIA HELLA is advancing its strategy of combining established battery and electronics expertise into integrated system solutions. The company aims to support automotive manufacturers in developing efficient and cost-competitive electrified vehicles while strengthening its position in the global automotive electronics market.
Overall, the two new contracts mark an important expansion of FORVIA HELLA’s integrated battery and power electronics business. By bringing together critical functions in the 3-in-1 high-voltage battery management system and 48-volt PowerPack, the company is positioning its EnergyCore solutions to address evolving vehicle requirements and contribute to the automotive industry’s transition toward affordable electrification.
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