FORVIA HELLA successfully launches first series production of highly integrated 48V Flatpack in China

• This product integrates two core functional components: the DC/DC converter and the battery management system
• The 48V Flatpack not only achieves enhanced performance but also offers significant advantages in lightweight design and cost efficiency

Shanghai, 2 July 2025. International automotive supplier FORVIA HELLA has introduced its innovative energy management solution, the 48V Flatpack, in China for the first time. This Flatpack integrates a 48V DC/DC converter and a battery management system, designed to meet the increasing demands for upgrading in vehicle electrical systems. This innovative solution significantly optimizes energy efficiency, reduces hardware size, and offers notable cost advantages. Developed by a multinational R&D team from FORVIA HELLA located in China, Germany, Romania, and India, it will be supplied as a subsystem to EVE, a renowned battery supplier in China and ultimately supports mainstream European luxury passenger cars. The product will enter series production in China in July this year.

Driving upgrades in vehicle electrical systems with automotive intelligence

With advancements in automotive technology, there are increasing needs for new vehicle functions, resulting in increased electrical loads. Traditional 12V electrical systems can no longer meet power demands. The 48V mild hybrid system has become an important alternative for providing stronger power support, with the core component, the 48V battery management system, being crucial for battery performance, protection, and optimization.

Innovative energy management solution: 48V Flatpack

FORVIA HELLA's 48V Flatpack perfectly integrates the DC/DC converter and battery management system into one single unit. This highly integrated design not only achieves bi-directional voltage conversion between 48V and 12V, meeting more low-voltage load power supply needs for the entire vehicle. The system can also optimize engine workload according to different driving conditions through functions like brake energy recovery and acceleration assistance, significantly improving vehicle energy efficiency. Its enhanced power output capability allows the vehicle to carry more loads, such as air conditioning and electric power steering, and provides additional power for hybrid vehicles, achieving faster and smoother acceleration, further enhancing the driving experience. In addition, the system features self-monitoring capabilities, effectively preventing short circuits, battery overcharging, and overheating issues without the need for additional voltage protection devices, showcasing higher reliability.

Highly integrated design: significant lightweight and cost advantages

Compared to existing single DC/DC and 48V lithium battery pack solutions on the market, FORVIA HELLA's 48V Flatpack significantly reduces the number of electronic components due to its highly integrated design, greatly reducing product size and simplifying wiring layout. This not only significantly improves product development efficiency, reduces development and manufacturing costs, but also facilitates vehicle layout for customers, providing more space and greater flexibility for vehicle design, achieving full model adaptation.

Over 20 years of experience in developing and manufacturing energy management solutions

Since 2003, FORVIA HELLA has been launching automatic start-stop intelligent sensors suitable for 12V micro-hybrid systems to the market, being one of the earlier component suppliers to enter the electrification market field. Today, FORVIA HELLA is one of the few automotive suppliers capable of providing a comprehensive electrification technology product portfolio, covering energy management and thermal management for various market segments from economic to luxury. The 48V Flatpack is another major innovation by FORVIA HELLA in this field. In collaboration with customers to develop the 48V Flatpack, FORVIA HELLA successfully met customer demands for higher integration hardware and higher standard software development, leveraging its profound R&D and production capabilities in energy management.

"We are very pleased to launch the innovative 48V Flatpack product, which not only demonstrates our technical strength in the electrification field but also reflects our deep understanding of customer needs. Through this solution, we hope to help customers improve automotive energy efficiency and drive the entire industry towards a more sustainable future”, says May Deng, Head of Product Center Energy Management within the Business Group Electronics China at FORVIA HELLA. “As the automotive industry's electrification transformation deepens, electric vehicle technology continues to develop, and FORVIA HELLA's technological innovation and business expansion in this field will also continue."