American automotive supplier BorgWarner Inc. is a global leader in electric vehicle (EV) engine manufacturing and powertrain electrification technologies, with a strong presence in the United States. Headquartered in Auburn Hills, Michigan, BorgWarner has a legacy spanning over 130 years, evolving from traditional combustion technology to become a pioneering force enabling the automotive industry’s transition to clean mobility. With extensive expertise in electric motors, inverters, power electronics, and drive-train systems, BorgWarner plays a pivotal role in shaping the EV ecosystem with innovative solutions designed for performance, durability, and sustainability.
Company Background and Strategic Focus
Founded in 1928 and publicly traded, BorgWarner specialises in producing advanced propulsion systems for passenger cars, commercial vehicles, and off-highway machinery. The company operates more than 90 manufacturing and engineering facilities in 24 countries, with a significant concentration in the United States. BorgWarner’s dedication to electrification has steered strategic investments in electric drive motors, power electronics, and integrated drive-train assemblies that accelerate the adoption of battery electric and hybrid vehicles.
BorgWarner’s vision emphasises delivering scalable, next-generation technologies such as high-voltage electric motors and silicon carbide-based inverter modules designed to boost efficiency, power density, and thermal management. The company targets diverse vehicle segments, ranging from electric passenger vehicles and SUVs to commercial trucks and off-highway applications, making it a comprehensive supplier for the emerging electric transportation landscape.
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Advanced Electric Motor Technologies
At the core of BorgWarner’s EV engine manufacturing is its cutting-edge High Voltage Hairpin (HVH) electric motor platform. The HVH 250 and HVH 410 series motors exemplify the company’s focus on power density, efficiency, durability, and customization to meet various performance criteria. These motors feature internal permanent magnet rotors, proprietary insulation systems ensuring durability, and oil or water-cooled configurations optimized for heavy-duty and off-highway use.
The HVH series motors operate efficiently at 700+ volts DC and are designed for direct drive, chain drive, belt drive, or integrated propulsion configurations. BorgWarner’s scalable motor design enables automotive OEMs to tailor power output and torque characteristics, with power capacities ranging between 100 kW to 500 kW, and torque outputs up to 650 Nm. These motor systems achieve peak efficiency of 95%, significantly enhancing vehicle range and emission reduction goals.
Power Electronics and Inverter Solutions
Complementing its electric motors, BorgWarner develops a comprehensive range of power electronics products, including silicon carbide-based inverters, DC/DC converters, and onboard battery chargers. Its 800-volt silicon carbide inverter technology delivers notable gains in energy efficiency and thermal management over silicon-based architectures, enabling faster charging and longer driving ranges in EVs.
BorgWarner’s patented inverter designs utilize dual-sided cooling and advanced power modules to minimize losses and maximize reliability. These innovations support high-performance electric drivetrains while addressing manufacturers’ cost and packaging constraints. The company also integrates sophisticated control algorithms and electronic controls, providing seamless communication between propulsion components for optimal real-world efficiency.
Contributions to Fuel Cell and Electrification Technologies
Beyond battery electric vehicles, BorgWarner applies its turbomachinery expertise to fuel cell technology. The company produces high-speed compressors and air supply systems that enhance fuel cell efficiency by recovering energy and improving durability. Such innovations expand BorgWarner’s reach into hydrogen-powered mobility solutions, diversifying its electrification portfolio and supporting future zero-emission transportation.
Industry Collaborations and Market Expansion
BorgWarner sustains strong partnerships with virtually every major automotive manufacturer worldwide, supplying electric motors and powertrain components for models across different electrification levels. Recently, BorgWarner secured multiple new electric motor projects with top Chinese domestic OEMs, underscoring its expanding footprint in the fastest-growing EV market globally. Production of these motors is slated to increase starting from 2025 and 2026 to support hybrid, plug-in hybrid (PHEV), and pure-electric vehicle platforms.
The company’s ability to adapt its innovative motor technologies to various voltages (400 V and 800 V platforms) and vehicle segments positions it well to meet accelerating global demand. Concurrently, BorgWarner continues to enhance manufacturing processes and invest in digital production systems to ensure product quality, scalability, and flexibility.
Commitment to Sustainability and Future Development
BorgWarner integrates sustainability into every phase of its operations—from eco-friendly manufacturing practices aimed at reducing waste and energy consumption to designing electric drivetrains that enable substantial reductions in carbon emissions. The company is committed to achieving carbon neutrality by 2035, aligning with global climate goals and pushing the automotive industry toward greener mobility.
Investments in R&D focus on lightweight materials, energy recovery systems, and thermal management improvements to push the boundaries of electric power-train efficiency. These efforts allow BorgWarner to continually enhance the performance and sustainability of vehicles equipped with its engines, ultimately benefiting the environment and consumers alike.
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Conclusion
BorgWarner exemplifies American leadership in electric vehicle engine manufacturing through its advanced electric motor solutions, state-of-the-art power electronics, and commitment to sustainable innovation. With a global manufacturing footprint, strategic OEM partnerships, and continuous technological advancement, BorgWarner stands as a critical enabler in the transition to cleaner, more efficient electric mobility. Its pioneering technologies and manufacturing expertise empower automakers worldwide to deliver the future of transportation—a low-emission, high-performance, electrified driving experience.