Battery Development for Electric Vehicles

From Technological Innovation to Series Industrialization

We push technology forward by focusing on getting products to market faster, increasing safety, and prioritizing recycling and sustainability. Furthermore, we create custom battery solutions for all types of vehicles, aiming to keep costs down and speed up the time to market. Our services cover everything from developing new concepts to perfecting the production process for large-scale manufacturing.

BEV Sedan Charging

The main challenge in vehicle electrification is developing effective batteries. Both new and established vehicle manufacturers face ongoing and emerging challenges as the technology evolves rapidly with each new market entrant. The focus is on optimizing efficiency, safety, and industrialization costs.

At AVL, we propel technological advancement by crafting customized battery solutions based on our customers' specific needs, aiming to reduce costs and accelerate market readiness. We handle all aspects of development, from initial innovation to preparing manufacturing processes for series production.  

Since 2007, we have concentrated on developing safe, cost-efficient, environmentally friendly battery systems with high energy density. Throughout the years, our focus has been on producing top-quality products with a strong emphasis on functional design and innovative production processes. We devise strategies for individual assembly steps and flexible small-batch production of modules and battery systems. The projects listed below represent just a few examples of our extensive work:

  • AVL Lighthouse

Our internal project to advance electrification by focusing on battery, EDU, and thermal system development and integration. AVL also leads the integration of E/E systems, control systems, vehicle aerodynamics, and chassis enhancements.

  • McLaren Speedtail

Battery pack development project from initial concept to start of production (SOP), incorporating modules into the battery pack for hybrid electric vehicle. The project was executed at the AVL Battery Innovation Center, where small series of battery packs were manufactured.

  • LG

Pouch module with a coated aluminum monoframe. Now produced in very large batches and installed in the Audi e-tron and Porsche Taycan, for example.

BEV Propolsion System
AVL Lighthouse

Development methodology

At AVL, we have the expertise, methods, and tools for the entire development process. These include simulation tools and service, virtual testing and validation, creation of prototypes, and integration into the complete vehicle.

BEV Propulsion - Side View

Innovative capability

We have been actively involved in automobile production for more than 75 years, and have optimized our processes for the swift transition from innovation to series-ready products. For batteries in particular, we focus on parallelization of functional and production process development.

Innovative Imersion Cooling
No Thermal Propagation

Our innovative battery concepts allow us to reduce CO2 emissions and increase the 24/7 safety of battery-electric vehicles. The key phrase is: no propagation. If a thermal runaway looks likely at cell level, flames must not spread to neighboring cells. Battery design of this type requires a detailed, careful development and verification process. We have developed a unique simulation methodology to realize this swiftly and in a cost-efficient manner. This combines physical tests at cell level with simulations at module and pack level - including the corresponding vehicle interfaces.

Volker Hennige

Weight savings, component reductions, easier assembly and service, as well as recycling aspects, all play a key role in the entire battery development process. AVL has already brought solutions with a high level of energy density to market, with low unit and production costs. Our expertise is a decisive advantage for future innovations.

- Volker Hennige, Skill Area Manager Battery at AVL

Cell Swelling
Battery Cell Development

AVL enables you to go beyond the limitations of standard cell formats. Electrochemistry, packaging, and safety – all combined with optimal mechanical, thermal, and electrical integration.

BEV Propulsion - Side View
Battery Modules and Packs

Benefit from our engineering expertise throughout the entire battery development process – from the initial idea to SOP and beyond. We offer a comprehensive set of services: in addition to engineering new batteries or derivatives, we support you in setting up cost-optimized, sustainable, and secure series production.

Battery Simulation
Simulation in Battery Development

AVL simulation software and methods enable fast and efficient development of no-propagation battery designs, structural cell integration, thermal systems for rapid charging, and many other solutions.

Battery BMS Rendering
Software and Controls for BEV

Our proven Battery Management System (BMS), developed in-house, facilitates safe battery control, both at the prototype stage and in series – including comprehensive diagnosis (OBD, ISO26262) and precise monitoring. Featuring its own software and hardware, the BMS is designed for all battery types and sizes.

 Battery Innovation Center
Battery Industrialization and Manufacturing

In addition to building, testing, and validating batteries, we also develop the associated industrialization for you at our AVL Battery Innovation Center. This allows us to provide production-ready development, including production planning and process validation.

battery testbed
Battery Testing Solutions

For battery (module/pack) testing, we offer complete test systems, stand-alone equipment, or even entire turnkey test labs.

As an independent service provider, AVL has been a leading battery technology company for nearly two decades.

From the electrode to the pack, we provide complete vehicle integration. We are pioneers, especially with regards to safety, we are already able to realize the no propagation objectives for the next generation of battery electric vehicles.

Our Battery Innovation Center (BIC) in Graz, opened in 2021, added another key future platform to our portfolio, enabling us to provide the best possible support for the automotive industry and its suppliers during the conversion to electromobility. The facility, which covers an area of 1600 square meters, supports all of AVL’s expertise in innovative battery concepts around the world, both in terms of functionality and production process development.

 Battery Innovation Center

Our global network of engineers and scientists provides the best possible connections for all vehicle disciplines. Wherever you are located – we are able to provide local support.

Global presence

20+

years of experience in battery development

650+

engineers in this segment around the world

900+

executed battery projects

25 %

year-on-year growth in battery development

45

global tech and engineering centers

10+

sucessful series developments

News

Moving steadily into the future: Find out what’s brand new in the field of battery development. 

simpulse-battery
AVL SIMpulse: Breaking Boundaries – Advance Battery Technology with Simulation
Digital

In the third edition of this series, we will dive into one of the major technology drivers for the automotive industry – battery technology. Our experts present solutions that break the boundaries of conventional battery design.

2021-04-12_webinar_batterielebensdauer_bild_landigpage
Battery Lifetime Prediction - Goals, Challenges, and Solutions
On-demand
Content Sustainable mobility is gaining increasing momentum. To improve value and profitability of the battery as most valuable component of electric vehicles, a smooth interaction of many stakeholders along the whole value chain of a battery and a d
Battery Development CV (1)
Battery Development Solutions for Commercial Vehicles
On-demand

Powertrain electrification poses new challenges and opportunities for every vehicle system, including the battery development for on- and off-road commercial vehicles. Battery systems for commercial vehicles – and their charging solutions – must be f

rendering acora
ACORA – A Revolution in Battery Cell Conditioning
On-demand

ACORA – A Revolution in Battery Cell Conditioning

Battery Testing Software
Performance Optimization for Battery Testing

How can the time to market for new batteries and electric vehicles be shortened? Explore our software solutions to learn how you can optimize your battery testing process.

AVL TechDay Battery
AVL TechDay Battery
55232 Alzey, Germany
On-Site

In our free AVL TechDay Battery we will focus on battery cell testing and validation and look forward to a day full of insights into exciting projects and interesting presentations.

Thermische Sicherheit
Thermal Safety in Battery Development
Upcoming

As the automotive industry accelerates toward electrification, ensuring battery safety becomes paramount. This insightful webinar explores the challenges, strategies, and emerging trends related to mitigating thermal runaway and propagation in lithium-ion battery applications.