Battery Cell Development

The Future of Development and Integration of Battery Cells

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.

Cell Swelling

The cell is the core of the battery system. Our expertise in this area encompasses the whole spectrum, from raw materials and their carbon footprint, through simulation of processes in the cell, to integration development.

In collaboration with universities and other leading institutions, we are continuously researching new solutions. In doing so, we are shaping future generations of battery cells and supporting suppliers in developing the right products for the automotive industry.

Our simulations and CAD models cover all construction variants – from standard to tabless design, and from pouch cell to other prismatic formats for power and energy cells. During integration we support you in achieving your defined performance targets at system level (pack or module).

Compared with the rapid advances in the electrochemistry of battery cells, the formats and housing forms have barely changed over the past 20 years. However, this aspect is increasingly coming into focus with the latest new developments. It is crucial for functional integration capacity, and thereby one of the central challenges when it comes to designing innovative cell-to-pack or cell-to-chassis implementations.

No Thermal Propagation
No Thermal Propagation

Optimized Performance 

Increasing energy density while maintaining low costs and high charging capacity. 

Function and Lifetime

Improvements to functions and a longer lifetime of cells and electrode stacks through electric, thermal, and mechanic simulations.

Thermal Safety

New designs that prevent cell runaway, ensure directed ventilation, and monitor break points.

Battery Cell Modelling

Our development services and our detailed consultancy services are founded on our research and analyses in the area of battery cells:

  • CAD modeling: Variety of designs from classic to “tabless”
  • System integration: Mechanical and thermal
  • Electrochemical and electrothermic analyses
  • Degradation analyses: SEI formation, particle crack formation, etc.
  • Mechanical analyses: Swelling and breathing, crash and crush, etc.
  • Thermal runaway analyses: Propagation time, increase in pressure, heat transfer, etc.

Integration with Function 

AVL is a leading organization in module development. This background enables us to design tailored cells and cell casings, and target increasing their integration capacity.

Ten Years of Experience with Cell Suppliers 

We know the battery cell market and take on the technical management of suppliers. With our validation and quality processes, we support the highest demands in the automobile supply chain. 

At the Forefront of Electrode Technology

Silicon anodes, solid state electrolytes, sodium ions – with our broad research expertise, we future-proof your battery project – no matter which electrochemical option you choose. 

Parametric Cell Designs

We develop precise CAD models for power and energy cells in any design variant. In line with the defined performance targets at system level, we optimize the CAD drafts with regard to their mechanical and thermal integration capacity and scalability.

Modeling and Analysis

Our electrochemical analysis of battery cells is based on the latest generation of electrochemical models; we also use equivalent circuit models (RC model) for our electrothermic analyses. To model abrasion and aging processes, we developed special degradation models, which can be used to model irreversible lithium plating, among other things.

Cell Simulations

We use sophisticated simulations to assess how the format and housing form impact the performance and lifetime of a battery cell. Using virtual models, we can identify and evaluate differences immediately. Based on this, we develop the appropriate cooling concept, to ensure that the desired performance and lifetime targets are met.

BEV Propulsion - Side View

AVL’s parametric cell designs opened up totally new possibilities for us – modular cell-to-chassis integration of the battery. I wasn’t previously aware of the positive effects this solution has on the cost structure and on the internal manufacturing strategy.

– Customer feedback after the project

Hungry for more? Gain more valuable insights through additional material.
Managing Change for the Better

An article on how AVL Process Innovation Services help you realize your development potential.


Related Topics

We are constantly working on new solutions. The following might be interesting for you:

BEV Sedan Charging
Battery Development for Electric Vehicles

We drive technological progress at AVL. 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.

Test Systems for battery cells
AVL Battery Cell TS™

For battery cell testing, we offer complete test systems, stand-alone equipment, or even entire turnkey test labs.

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.

E-Storage SiC Visual
Battery Test and Emulation Products

Best-in-class measurement & control accuracy combined with highly dynamic performance for battery, e-drive and fuel cell systems testing.

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

Press Release
AVL Opens New Battery Innovation Center

Optimized development of battery functions and manufacturing processes

Press Release
AVL Opens New Center for Mobility and Sensor Testing in Roding

Innovative Test Infrastructure for Driver Assistance Systems and Autonomous Driving

Do you have questions or want to work with us?

Our experts are happy to help.

You are currently on the AVL Global Site. Click below if you would like to switch to