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Rising gas prices at the fuel station, stronger emission requirements at the tail pipe have required more and more fine-tuning of the internal motor components. To support the customers in this difficult task, MAHLE has developed a Power Cell Unit (PCU). The newly introduced lightweight PCU with the MAHLE patented ECOFORM® piston, an optimized pin and high strength material connecting rod offers the customer a complete system that is focused on less reciprocating masses, lower friction and better NVH. The PCU as a unit has been developed for each and every component as well as the interaction of all these components to additionally benefit the customer with less program management, organization, logistic and reduction of development time because all parts are made in-house by MAHLE. An example using a conventional PCU in production versus a weight optimized version is provided for comparative purposes.

The manufacturing of modern engines requires an optimization down to component level. Near net shape connecting rods with high fatigue strength are opening a range to reduce costs and improve the engine's performance. In the last years the development of production technology for steel-forged rough parts was continued aiming at a reduction of the required machining steps. Simultaneously the benefit of high fatigue strength for the forged steel compared to alternative powder metal material can be maintained.