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Accelerate the Change
for E-Mobility
It starts with curiosity.
AVL embeds sustainability into every project by optimizing CO₂ footprint, energy use, and material efficiency from concept to production, leveraging Design-to-CO₂ methods, reduced rare materials, recycling strategies, and energy-efficient testing to enable responsible, future-ready mobility.
For us, sustainable E-Mobility engineering means:
- Predictive Energy Management
- Predictive Health Monitoring
- Safe Battery Design
- Design for Recycling
- Material-Saving Concepts
- Usage of Alternative Materials
AVL develops propulsion systems that deliver high performance and reliability at optimized cost and resource efficiency through system-level design, lightweight architectures, and virtualized development, reducing weight by up to 30% and system costs by around 15% across all vehicle classes.
This is how we make E-Mobility affordable:
- Tool to Evaluate 100,000+ Powertrain Combinations
- Usage of GaN Inverter Technology
- OBD & Diagnostics
- AVL Battery Composer: AI-supported Parametric Modeling
AVL accelerates development cycles with AI-driven simulation and automated testing, enabling early system validation, reducing risk, and helping manufacturers reach production readiness faster while maintaining benchmark reliability and durability
This is how we accerlate time to market:
- AVL PaViL: 24/7 automated Vehicle-in-the-Loop Environment
- Virtualization: Software-in-the-Loop
- High-accuracy SoC and SoH Estimation
- Digital Twins and AVL Load Matrix™ for Battery DVP Optimization
- Model-Based Systems Engineering
- Modular EDU and Transmission Design
- AVL Motbas-e Database to Save up to 60 % in Cost
- Advanced Simulation & Calibration
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AVL shortens development cycles through the consistent use of AI-supported virtual tools, simulation, and automated test environments. Integrated toolchains and validated processes allow early system validation and minimize development risks. This enables customers to achieve production readiness in significantly less time while maintaining benchmark reliability and durability standards. The result is faster, more reliable development that helps manufacturers meet their launch targets with confidence.
- Predictive Energy Management
Anticipates future load demands to allocate energy efficiently, enhance charging efficiency by predictive thermal management. Ensuring vital systems like braking and steering receive priority and enhancing both safety and overall efficiency.
- Design to CO₂
Lifecycle-based CO₂ assessment drives material, design and manufacturing process decisions using eco design methods, thus cutting emissions from concept to recycling.
- Battery Passport
Digital lifecycle documentation increases transparency on performance, recycled content, and supply chain compliance, enabling responsible material use and circular traceability.
- Safe Battery Design
Unique simulation models and methods enable no-propagation battery concepts that eliminate thermal runaway risk, ensuring passive safety and long-term reliability even with high-energy density chemistries.
- Design for Recycling
Integrates recyclability early in design, using eco-friendly materials and life-cycle costing to reduce waste, support a sustainable supply chain by enabling a circular economy.
- Material-Saving Concepts
Lightweight design and optimized material use reduce resource material consumption and product CO2 emissions without compromising performance.
- Alternative Materials
Incorporates bio-based composites and recycled metals to lower environmental impact.
- Predictive Health Monitoring
Data-driven diagnostics detect component degradation early, reducing downtime, extending useful life, and maximizing resource efficiency.
- High-Speed E-Machine Concept
30,000 rpm e-motor design using standard materials minimizes use of rare earth materials and copper, reducing CO₂ footprint while achieving high-power density and performance.
Explore our solutions — discover what’s driving the future of E-Mobility.
AVL Digital Battery Passport
The only fully operational digital battery passport solution in a productive battery environment.
7 Trends in Automotive Sustainability
Seven trends that highlight the automotive industry's efforts to achieve sustainability goals by addressing emissions across the entire value chain and adopting greener energy sources and production practices.
Energy Ecosystem
Making the best engineering methods and tools available to solve the task of the century: An Energy System based on Renewables
Environmental Sustainability
Environmental Sustainability
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AVL develops propulsion systems that combine high performance and reliability with optimized cost and resource efficiency. By applying a system-level design approach, material use and complexity are reduced. For instance, compact high-speed drive units can achieve up to 30 percent lower weight and around 15 percent lower system costs. Scalable architectures and strongly virtualized development methods ensure cost-effective implementation across all vehicle classes, from high-volume models to premium applications.
- Powertrain System Optimization:
Analyses more than 100,000 combinations of powertrain architectures and components within only 4 weeks in the pre-concept & feasibility phase to define cost-optimal configurations by balancing performance, energy efficiency and range to accelerate SOP decisions and cutting redesign loops.
- OBD & Diagnostics:
Optimized BEV and hybrid OBD & diagnostic systems reduce repair costs, improve workshop efficiency, and prevent unnecessary breakdowns through faster, more precise fault identification. All that within reduced development time.
- Battery Composer:
AI-supported parametric modeling enables rapid concept generation, reducing early-phase development time and engineering cost while maintaining flexibility and precision.
- Battery DVP Optimization:
Digital twins, AVL Load Matrix™, and risk optimized planning minimize physical tests, saving cost and time without compromising product quality.
- GaN Inverter Technology:
SiC-level efficiency at IGBT-level cost. Smaller, lighter power electronics with longer power stage lifespan enables scalable, cost-effective electrification.
Explore our solutions — discover what’s driving the future of E-Mobility.
Battery Development for Electric Vehicles
Based on the individual requirements of our customers, we develop tailored battery solutions for all types of vehicles. Our goal is to meet cost objectives and minimize the time to commercial rollout. AVL covers the complete spectrum of development – from innovation to process development for series production.
Electric Driveline Development
The rising demand for e-drive solutions requires a high level of development capacity and expertise. We support you in your transformation process with holistic advice, as well as innovative development and testing solutions – from individual components, to software, to integrated systems. To get your propulsion system market-ready
Power Electronics and Software
Customer-specific development of power electronics – from prototypes to series products. Our engineering services include hardware and software, safety and security, EMV optimization, tests and validation, as well as support for industrialization.
E-Mobility Engineering
In the greatest transformation of the automotive industry, the focus is shifting towards simple, fast, cost-effective, and sustainable mobility. The paradigm shift this involves is also changing the way that vehicles are designed, developed, and built.
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AVL shortens development cycles through the consistent use of AI-supported virtual tools, simulation, and automated test environments. Integrated toolchains and validated processes allow early system validation and minimize development risks. This enables customers to achieve production readiness in significantly less time while maintaining benchmark reliability and durability standards. The result is faster, more reliable development that helps manufacturers meet their launch targets with confidence.
- AVL PaViL
24/7 automated vehicle-in-the-loop environment enabling full powertrain and subsystem reproducible testing under any condition. PaViL reduces the required number of prototypes and cuts development time dramatically.
- Virtualization
Software-in-the-Loop (SiL) testing incorporating physics-based plant models validates functions virtually, accelerating calibration and improving software quality while reducing the need for physical prototypes.
- Battery DVP Optimization
Digital twins, AVL Load Matrix™, and risk optimized planning minimize physical tests, saving cost and time without compromising product quality.
- Battery Core Functions
High-accuracy SoC and SoH estimation, even for LFP chemistry, ensures safer batteries, faster development loops, reduced calibration time and best SoC and SoH prediction quality for the end-user.
- Model-Based Systems Engineering
Handling complexity, re-use of existing solutions and accelerated development speed through enabling an early & deep system understanding. This supports also efficient trouble solving, variant-development and lifecycle maintenance.
- Modular EDU and Transmission Design
Scalable architecture significantly accelerates the design process for cost-effective EDU-systems, enabling faster integration and SOP readiness.
- AVL Motbas-e
Instantaneous e-motor design tool cutting concept development time from over a month to less than a week, saving up to 60 % in cost.
- Advanced Simulation & Calibration
Integrated virtual and real-world methodologies shorten validation cycles while ensuring system accuracy and regulatory compliance.
Explore our solutions — discover what’s driving the future of e-mobility.
Electric Driveline Development
The rising demand for e-drive solutions requires a high level of development capacity and expertise. We support you in your transformation process with holistic advice, as well as innovative development and testing solutions – from individual components, to software, to integrated systems. To get your propulsion system market-ready
Battery Development for Electric Vehicles
Based on the individual requirements of our customers, we develop tailored battery solutions for all types of vehicles. Our goal is to meet cost objectives and minimize the time to commercial rollout. AVL covers the complete spectrum of development – from innovation to process development for series production.
Transmission
At AVL, we have in-depth understanding of the individual components and solid system expertise. With us, you can develop your electric drive systems efficiently, powerfully, conveniently, and cost-effectively. And all with a low weight.
Solutions for the Virtualization of Development Processes
Virtualize your development process from configuration to SOP.
E-Mobility Simulation
The sharp rise of carbon dioxide in the air and the associated global warming have led to the automotive industry being faced with the task of finding mobility solutions that have less impact on the environment. Electrified propulsion systems are a promising solution. This is shown not only by the development activities, but also...
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