Hyundai Motor Company has officially begun preparation for mass production of its first extended-range electric vehicle (EREV), the Santa Fe EREV, according to ETNews report. The company plans to complete development of the internal combustion engine and the essential engine control unit (ECU) by the first half of 2026. These components will be applied to Santa Fe EREV prototypes to evaluate driving performance, durability, and overall quality through comprehensive testing cycles.
Mass Production in Late 2026, Global Sales in 2027
Hyundai aims to start mass production of the Santa Fe EREV at the end of next year, with global sales targeted for 2027. The rollout will begin in North America, a key region with strong demand for mid- to large-size SUVs, and will expand to global markets afterward.
Key Partners Supporting Santa Fe EREV Development
Development of the ECU for the EREV is being led by Hyundai Kefico. The company will use HIL (Hardware-in-the-Loop) system equipment supplied by domestic manufacturer dSPACE to validate proper ECU operation.
Hyundai Mobis is also participating, developing control systems for the SUV’s battery and electric motor in collaboration with Hyundai Kefico to support Hyundai’s mass production timeline.
Hyundai will leverage this facelift to introduce Pleos Connect.
Expected to Lead the Global EV Market with Longest Range
The Santa Fe EREV is projected to deliver nearly double the driving range of the IONIQ 6 (562 km), Hyundai’s longest-range pure EV. Thanks to its extended-range powertrain, the Santa Fe EREV is expected to become a highly competitive model in the global EV segment.
EREV technology is gaining traction worldwide. Major automakers such as Volvo have begun developing similar solutions, while Chinese manufacturers are aggressively expanding EREV lineups. BYD is already selling its premium Yangwang EREV SUV, and Xiaomi is developing the high-performance YU8 EREV.
Potential Production at Hyundai’s New U.S. Plant
Industry sources suggest that the Santa Fe EREV may be produced at Hyundai Motor Group’s new facility, Hyundai Motor Group Metaplant America (HMGMA), in the United States. Following mass production, Hyundai is expected to aggressively market the Santa Fe EREV not only in advanced markets such as the United States and Europe but also in fast-growing Asian markets where Chinese EV brands are rapidly increasing their market share.
