xEV Battery Applications

Volkswagen AG plans to massively increase the proportion of electric vehicles by 2030. The focus of battery development is on attractive products in the segments Affordable, Range & Performance. With the help of standardized components, the complexity and diversity of variants in the development, series production, after-sales and recycling of HV batteries will be minimized. Focus of this presentation will be on the electrics and electronics architecture of current and future BEV platforms as well as the design guidelines for optimising customer value with minimized variance.

The new all-electric Porsche Cayenne features innovative battery technology. The presentation covers mechanical architecture from cell to HV battery, with the module being Porsche’s first in-house production, and also addresses the efficient cooling system. Key KPIs such as fast-charging capability, power performance, and function-integrated design are emphasised. Attendees will gain in-depth insights into technical advancements and challenges in electromobility.

BMW has introduced with the BMW iX3 the sixth-generation BMW eDrive technology, which sets new standards for efficiency and long-distance capability. Development of such an innovative technology requires a thorough understanding of battery cells. The BMW group has shown that battery cell designs can be influenced by the so-called Electrolyte Motion induced Salt Inhomogeneity (EMSI-effect). This presentation will focus on a solid mechanical perspective of the EMSI-effect by modelling the granular behavior of the porous coating in an anode.

General Motors is building an electrification powerhouse, having launched a dozen EVs into the market, ranging from the Equinox EV to the Cadillac Escalade IQ. Mr. Oury will provide an update on GM’s battery strategy, focusing on engineering the right battery for the right vehicle—aligning performance, cost, and range with customer needs.

With the increasing market share of electrified vehicles and the continuously rising numbers of traction batteries, there is also a demand for battery service and repair. The traction battery is often the most valuable component of the vehicle and represents very valuable resources that need to be maintained with respect to sustainable mobility. Stellantis has set up refurbishment centers within Europe based on the experience gained in Rüsselsheim since 2011. Traction batteries of various types can be analysed and repaired. The talk will explain the integrated methodology for root cause analysis and repair of defective battery packs at Stellantis.

Long-haul trucks operate under duty cycles that differ substantially from those of passenger cars and other light vehicles. However, cell lifetime is still commonly assessed using uniform 1C testing. This work presents a methodology that replaces this one-size-fits-all approach with a truck-specific ageing procedure based on recorded field data. The resulting test protocols reveal significant differences in degradation behavior, enabling more accurate service-life prediction and more informed cell selection for heavy-duty electrification.

This presentation outlines the roadmap connecting battery cell chemistry, cost drivers, and localisation strategies in a rapidly evolving global market. We highlight how material choices, design and supply-chain configuration shape cell cost competitiveness, and examine the impact of currency fluctuations on long-term sourcing decisions. The talk provides a concise view of the key technical and economic levers needed to optimise future battery programs, balancing chemistry innovation, localized manufacturing, and Forex risk management.

Battery swapping is emerging as a holistic solution that bridges vehicle applications and grid services, redefining energy delivery for electric mobility. Unlike ultra-fast charging, swapping enables rapid battery replacement—typically in under five minutes—while maintaining grid stability and battery health. This decoupling of energy replenishment from time and infrastructure constraints offers unmatched convenience, scalability, and operational predictability. Standardized battery packs, as demonstrated by NIO’s approach, support modular upgrades in chemistry, thermal management, and diagnostics, ensuring backward compatibility and continuous innovation. Beyond convenience, swap stations can act as distributed energy hubs, integrating renewable sources and enabling demand-side management. This transforms batteries from static components into dynamic assets that support vehicle performance, second-life applications, and grid balancing. By combining user-centric mobility with smart energy ecosystems, battery swapping delivers a sustainable, upgradeable, and service-oriented model—positioning it as a cornerstone for future EV infrastructure and grid-interactive energy systems.

The transition to net‑zero emissions requires a major reduction in internal combustion engine vehicles, positioning electric vehicles (EVs) as the primary alternative. Many EVs use batteries larger than necessary for typical daily travel, leading to higher costs, lower efficiency, and longer charging times. This study evaluates whether smaller batteries can meet routine driving needs while reducing energy consumption, charging duration, and overall costs. Modelling shows that downsizing batteries can improve efficiency, shorten charging times, and lower purchase and operating costs. A 30% reduction could save around £2,650 and increase efficiency by up to 8%.

Challenges to the battery supply chain have never been more significant than they are now, and critical minerals have come to the forefront of global discussion. This presentation will cover forecasts for the supply, demand, and price of key battery materials along with potential disruptions including export controls, capacity challenges, and demand shifts.

As the EU moves toward a circular and climate-neutral economy while aiming for boosting its competitiveness, the regulatory framework for batteries is evolving rapidly. Representing the European Commission’s Joint Research Centre (JRC), this presentation provides a strategic update on the implementation of the EU Batteries Regulation, looking at the latest developments in omnibus amendments, implementing legislation and the rollout of the Battery Passport. Beyond policy, the session will detail the JRC’s role in bridging the gap between legislation and technical reality through harmonized standardisation. Finally, a holistic view of the European battery ecosystem's trajectory will be provided through identifying current market trends.

As battery safety regulations tighten, advanced fire protection materials are key to safer, lighter, and more flexible EV battery designs. This presentation surveys different approaches from battery packs on the road, system-level and material-level validation methods, and highlights recent advances in polymeric material research.

Recent market developments highlight the need for customer-focused xEVs with high autonomy and competitive pricing. While the rise of cylindrical cells supports adaptability to different powertrain architectures, growing significance of sustainability and supply chain resilience in response to global uncertainties influence cell chemistry choices, with direct implications on pack design. This presentation introduces a scalable cell-to-pack approach employing cylindrical cells emphasising cost and weight reduction while maximising volume utilisation, thus offsetting penalties associated with low energy density chemistries. The design eliminates potting, improving heat transfer, charging rates, and reparability while maintaining safety, offering cost-effective autonomy “rightsised” for the respective application.

The CEA's battery prototyping and processing laboratory has the advantage of being versatile. It can produce industry relevant electrodes (from centimeters to several meters in length) to manufacture prototypes of various sizes (0-10Ah). This scale allows for the evaluation of numerous KPIs for mature chemistries, as well as the exploration of new processes (reduced solvent or dry) and new generations of batteries (Gen4, Gen5). To illustrate this, the collaboration between the CEA and Stellantis will be presented.