Global Commercial Vehicle Thermal System Market Assessment, By Vehicle Type [Light Commercial Vehicle, Medium Commercial Vehicle, Heavy Commercial Vehicle], By Application Type [HVAC, Powertrain Cooling, Fluid Transport, Others], By Propulsion Type [Internal Combustion Engine, Electric], By Region, Opportunities and Forecast, 2018-2032F

Global commercial vehicle thermal system market is projected to witness a CAGR of 12.93% during the forecast period, 2025-2032, growing from USD 32.79 billion in 2024 to USD 86.74 billion in 2032F. The global commercial vehicle thermal system market is witnessing growth, driven by rising emission targets, electrification of freight fleets, and increased demand for energy-efficient operating models. With logistics networks focusing on sustainability, the latest thermal management solutions have become critical in maximizing battery output for electric trucks and ensuring drivetrain efficiency for traditional fleets.

Report Attributes	Details
Base Year	2024
Forecast Period	2025-2032F
Historical Period	2018-2023
Projected Growth Rate	CAGR of 12.93% between 2025 and 2032
Revenue Forecast in 2032	USD 86.74 billion

Advancements in predictive thermal analysis and lightweight materials facilitate accurate heat dissipation and reduction of parasitic energy loss. OEMs are incorporating modular thermal systems that are compatible with various powertrains, ranging from diesel hybrids to zero-emission platforms. The growth of autonomous long-haul trucks and refrigerated vehicles requires strong thermal resilience in extreme climatic conditions. Collaborations between major energy firms and component suppliers are advancing R&D in cryogenic cooling and waste heat recovery, pushing the boundaries of thermal system capabilities. This shift establishes thermal management as a key differentiator for commercial vehicle performance, reliability, and overall cost of ownership.

For instance, in September 2024, Bosch Rexroth AG partnered with Modine Manufacturing Company to integrate Modine's EVantage thermal management systems into Bosch Rexroth’s eLION product line for electrified off-highway equipment globally. This collaboration enhances the eLION systems with advanced thermal management, supporting the shift toward electrification in off-highway machinery by offering high-performance and low-emission EV solutions.

Product Launches Bolster the Global Market Demand

Product launches are driving the demand for thermal systems in commercial vehicles, with OEMs launching combined thermal management platforms tailored to next-generation commercial vehicles. Automakers are launching multi-zone air-conditioning and heating systems for electric trucks to ensure battery, cabin, and cargo temperature optimization. Modular thermal structures now allow complete hybridization to be achieved seamlessly, with fleets being capable of switching between energy sources without retrofits. Startups are disrupting the industry with AI-powered thermal routers that dynamically allocate cooling resources based on real-time operational data. These technologies improve performance in EVs and optimize combustion engine performance, making thermal systems a hub theme in vehicle design. Fleet operators increasingly appreciate these technologies to meet sustainability targets and reduce downtime, strengthening thermal innovation as a cornerstone of commercial mobility.

For instance, in September 2024, XING Mobility Inc., a worldwide leader in immersion cooling battery technologies, introduced its newest product, the IMMERSIO XM28, at IAA Transportation 2024, highlighting the electrification of medium and heavy-duty commercial vehicles. IMMERSIO XM, rigorously tested and certified by leading automotive manufacturers, offers competitive prices, modular design, and advanced thermal management, making it ideal for commercial vehicles.

Growing Hydrogen-Powered Truck Drives the Market

Hydrogen fuel trucks are changing the trend of thermal system demands, imposing cryogenic coolants on fuel cell stacks and hydrogen storage liquid. Thermal designers currently struggle to handle extremely low temperatures while reducing boil-off loss as much as possible during hauls. Complex heat exchangers and vacuum-insulated pipes are becoming central technologies, providing seamless energy exchange between fuel cells and drive trains. Collaboration between automotive and aerospace thermal experts is producing military-grade insulation materials adapted for the commercial market. In parallel, waste heat recovery technologies are being optimized to transfer surplus thermal energy into power, improving vehicle efficiency. As hydrogen infrastructure grows, thermal systems with dual-temperature regulation for fuel cells and conventional cabin comfort are becoming vital, making hydrogen trucks a major growth driver.

For instance, in January 2024, the business of Rheinmetall AG concerning thermal management continues to grow as it received an order for an innovative plug-and-play heat pump solution to be used in a hydrogen-powered truck. The complete system can be integrated into new and existing vehicle platforms.

Light Commercial Vehicles Lead the Global Market

Light commercial vehicles (LCVs) lead market growth due to surging e-commerce logistics and city centre delivery electrification. Last-mile delivery networks need compact, high-performance thermal solutions that address the demand for battery thermal management and cargo compartment climate control. OEMs are utilizing split-system architectures where drivetrain and payload temperatures are individually controlled, essential for perishable commodity transport. The growth of electric vans has driven demand for quiet, vibration-free thermal pumps and light condenser units. Aftermarket retrofitting upgrades to equip existing fleets with intelligent thermal controls also drive segment growth. Decarbonization pressures on urban freight operations coincide with LCV-specific thermal technologies, including regenerative thermal systems that use braking energy to heat cabins. This intersection of operational utility and regulatory coincidence solidifies LCVs' market dominance.

For instance, in June 2024, Vibracoustic Group launched a cutting-edge Thermal Management Decoupling System for battery electric vehicles (BEVs), including commercial vehicles. This system enhances the integration of thermal technologies such as HVAC, optimizing space, efficiency, and assembly. Proven through rigorous testing, it is ready for serial production.

Asia-Pacific Dominates the Global Market

Asia-Pacific leads the highest market share, driven by China's rapid electrification of commercial fleets and India's initiatives to modernize logistics. Stringent thermal efficiency regulations enforced by regional governments to ensure emissions compliance drive the adoption of cutting-edge cooling systems. Japan's leadership in hydrogen mobility and South Korea's semiconductor-based thermal sensor technologies build a strong ecosystem for next-generation solutions. Southeast Asia's growing cold-chain logistics industry focuses on multi-temperature zone architectures, whereas Australian mining requires thermalized architectures to be ruggedized. Local producers use cost-competitive manufacturing volumes to corner budget segments, whereas international players form joint ventures to tap into specialist tech niches. The region's dual focus on electric and hydrogen commercial vehicles positions it at the forefront of thermal system innovation, driven by unmatched manufacturing flexibility and policy-led market development.

For Instance, in April 2025, in China, Geely’s Farizon New Energy Commercial Vehicle Group (Farizon Auto) and Bosch Commercial Vehicle Group signed a strategic agreement to co-develop methanol-hydrogen electric technologies and expand globally. The collaboration will integrate Bosch’s fuel electronic control systems, e-drive units, thermal management, braking systems, and smart driving solutions with Farizon’s electric, methanol-hydrogen, and fuel cell commercial vehicles.

Impact of U.S. Tariffs on Commercial Vehicle Thermal System Market

U.S. tariffs on thermal system components are compelling supply chain realignments, particularly affecting Asian exporters of radiators and electric compressors. Domestic manufacturers face cost inflation but gain competitive insulation, spurring investments in localized production of high-value subsystems like thermal control modules. Tariffs accelerate R&D in alternative materials, such as graphene-enhanced heat exchangers, to circumvent duties on traditional metals. North American OEMs are redesigning thermal architectures to minimize tariff-exposed parts, favoring integrated modular systems over discrete components. Meanwhile, Asian suppliers pivot to tariff-exempt markets in Africa and South America, leveraging trade agreements. While tariffs temporarily disrupt pricing stability, they incentivize technological sovereignty in thermal innovation, with long-term implications for global market fragmentation and regional specialization in subsystem production.

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Report Scope

“Global Commercial Vehicle Thermal System Market Assessment, Opportunities and Forecast, 2018-2032F”, is a comprehensive report by Markets and Data, providing in-depth analysis and qualitative and quantitative assessment of the current state of global commercial vehicle thermal system market, industry dynamics, and challenges. The report includes market size, segmental shares, growth trends, opportunities, and forecasts between 2025 and 2032. Additionally, the report profiles the leading players in the industry, mentioning their respective market share, business models, competitive intelligence, etc.

Report Attribute	Details
Segments Covered	Vehicle Type, Application Type, Propulsion Type
Regions Covered	North America, Europe, South America, Asia-Pacific, Middle East and Africa
Key Companies Profiled	·       Robert Bosch GmbH, Dana Incorporated, MAHLE GmbH, Gentherm Inc, Hanon Systems, DENSO Corporation, BorgWarner Inc., Modine Manufacturing Company, Schaeffler AG, Eberspächer Gruppe GmbH & Co. KG
Customization Scope	15% free report customization with purchase
Pricing and Purchase Options	Avail the customized purchase options to fulfill your precise research needs
Delivery Format	PDF and Excel through email (subject to the license purchased)

In the report, the global commercial vehicle thermal system market has been segmented into the following categories: 

• By Vehicle Type
  • Light Commercial Vehicle
  • Medium Commercial Vehicle
  • Heavy Commercial Vehicle
• By Application Type
  • HVAC
  • Powertrain Cooling
  • Fluid Transport
  • Others
• By Propulsion Type
  • Internal Combustion Engine
  • Electric
• By Region
  • North America
  • Europe
  • South America
  • Asia-Pacific
  • Middle East and Africa

Key Players Landscape and Outlook

The market features established giant companies vying with EV-focused disruptors and hydrogen specialists. Differentiators include patents in phase-change materials, AI-optimized thermal routing, and modular system scalability. Suppliers compete through vertical integration, with leaders controlling everything from sensor production to cloud-based thermal analytics platforms. Strategic alliances dominate—thermal firms partner with battery manufacturers to co-develop cell-specific cooling solutions. Regional champions in Asia leverage cost leadership, while European players excel in premium efficiency systems. Startups attract funding with niche innovations like self-healing thermal fluids or magnetocaloric cooling. The landscape increasingly rewards those mastering cross-platform compatibility, enabling thermal systems to serve electric, hybrid, and hydrogen trucks simultaneously.

Key Players Operating in the Global Commercial Vehicle Thermal System Market are:

• Robert Bosch GmbH
• Dana Incorporated
• MAHLE GmbH
• Gentherm Inc
• Hanon Systems
• DENSO Corporation
• BorgWarner Inc.
• Modine Manufacturing Company
• Schaeffler AG
• Eberspächer Gruppe GmbH & Co. KG

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