Battery Engineering

EVE-Ai Battery Fleet Analytics addresses key challenges across EV fleets and stationary storage, including limited battery visibility, unplanned downtime, uncertain lifetime, and fragmented data. Its unified cloud–edge intelligence layer converts raw streams into predictive, actionable insights for performance and safety. The platform delivers real-time SoH, SoC, RUL, early fault and anomaly detection, as well as prescriptive recommendations tied to business value. Powered by adaptive models, digital twins, and a learning AI agent, it scales across chemistries and asset types, supporting EV, BESS, grid, and renewable integration.

The market for utility scale battery energy storage systems (BESS) is growing rapidly and the numbers of planned BESS installations in Europe are skyrocketing. While this is great news for the energy transition, it creates challenges for operators as well as project developers and integrators. They have to be fast and deploy hundreds of MWh of batteries—at the same time they need to secure the invested assets by considering resilience against cyber attacks from an early project stage until end of life.

This talk delves into the operational insights gained from Battery Management System (BMS) data. It highlights key metrics, data analysis techniques, and their role in monitoring battery performance, ensuring safety, and optimising system efficiency during real-world operation.

Innovative battery diagnostics, key to high performance and safe systems, are emerging across Europe. Our projects explore prototype cells with distributed thermal arrays, fibre-optics, reference electrodes and other for battery optimisation and self-healing. These adaptive methodologies suit various systems and industrial applications. Integrating new monitoring solutions into cells and battery management systems provides unprecedented insights into battery state for characterisation, prototyping, and optimisation.

To reach the necessary energy density, one strategy is to increase silicon content in the anode. In addition to a profound, age-dependent hysteresis, blend anodes show a multitude of aging paths for OCVs. This talk will highlight the impact of changing OCVs on conventional state estimation methods and show best practices on how to quantify these effects on cell level in the lab.

In this presentation recent changes in the regulatory requirements for safety testing of battery electric vehicles and, where applicable, their batteries are discussed.

This presentation examines the mechanisms and impacts of self-discharge in lithium-ion batteries, highlighting diagnostic methods to identify degradation pathways. Understanding self-discharge behavior supports improved battery health assessment, performance prediction, and safety management across diverse applications.

In the last years we performed numerous calendar and cyclic ageing studies to assess the safety level of significantly aged commercial cylindrical cells using the heat-wait-seek test in the ARC. The results reveal significant correlations between storage/operating temperatures, charge/discharge rates, and critical safety parameters, which are onset, venting and thermal runaway temperature. Insights from this study provide valuable guidance for optimizing the thermal and safety management strategies to enhance the longevity and safety of lithium-ion cells in first and second life applications.

Lithium-ion battery safety remains one of the most critical technical challenges for electric vehicle users across transportation sectors. This talk will explore key safety concerns related to battery failure, with a particular focus on thermal runaway phenomena, contributing factors, and implications for electric vehicle design and operation. Emphasis will be placed on real-world safety considerations, emerging mitigation strategies, and the importance of coordinated technical and organisational approaches to addressing these risks.

Exposing Li-ion batteries to temperatures above 60°C leads to thermal degradation and potentially thermal runaway. This talk gives an insight into these processes including the underlying reaction network at the electrodes and in the electrolyte. Operando electrochemical mass spectrometry reveals a temperature-triggered complex sequence of various degradation gases during heating; the evolution pattern is reproduced by kinetic models, which give an unprecedented insight into the occurring reactions and crosstalk.

In this talk, we introduce a methodology that combines aging measurements, intermediate characterisations, and physical aging models and exemplify it through a case study involving the Molicel INR21700-P50B cell. The underlying idea is to use optimised routines to identify aging physically along the different trajectories of aging tests and to integrate the parameters to simulate the full behaviour of aged cells under all scenarios.

New generation batteries, including Li-ion, require the application of operating pressure, which is of strategic importance in cell operation. In addition to the pressure value, the uniformity of pressure distribution across the cell is critical, especially when the cell volume varies during use. The Intelligent Cycling System developed by Hydro-Québec allows the application of isostatic hydraulic pressure, in addition to dynamically regulating the pressure and operating temperature of the cells to operate them optimally.

This talk outlines an advanced electrode engineering approach to architected and dry-processed battery electrodes, leveraging field- and laser-assisted strategies—micro-electric-field (μ-EF) casting and femtosecond-laser structuring—together with dry-processing routes. These methods control particle alignment, porosity, and ion-transport pathways to realize hyper-thick electrodes up to ~1000 µm with high areal capacity and stable cycling. Case studies will show how the resulting architectures improve rate capability and durability while enabling scalable, solvent-lean manufacturing.

Which cell to use, 2170, 46xx, or pouch cell? How to size a battery pack for an electric aircraft? These are the typical questions in battery engineering for electric aircraft. The talk will get into the basic of Li-ion battery design with tangible aerospace best practices.