Industry Insight: How are Electric Vehicle Batteries made? 

Electric vehicles are undoubtedly the future of motoring. In order to ensure this future is as efficient and safe as possible, the fundamentals of how electric vehicle technology works need to be streamlined and harnessed, but how are electric vehicle batteries made? 

In order to power an electric vehicle, a battery is needed in place of the fuel tanks we are so familiar with. Just like our phones and laptops, electric vehicle batteries are charged up using electricity, which then is used for power. Whereas the batteries for most gadgets have a defined time before they are depleted, EV batteries have a ‘range’ – i.e., a distance that the car can travel before the batteries run out of charge. After this, they will need to recharge again.   

These batteries need to store as much energy as possible to minimize range anxiety, as well as maintain safety in case of unexpected events.  

Simulation and Advancement of Battery Technology | How are electric vehicle batteries made

So, how are Electric Vehicle batteries made?

Battery Design and Development 

Batteries are highly complex systems, requiring advanced engineering methods at all levels: from chemistry to cell engineering, to module and pack engineering, and finally integration into full vehicles. There is a lot for battery manufacturers to consider and implement into processes to ensure that battery designs are of the highest standard and quality and meet the needs of customers. Find out more about how we can assist you with this process in our on-demand webinar ‘Battery Design from Chemistry to System’. 

Battery Materials 

EV batteries are made from a combination of raw materials. ‘Base’ metals such as aluminium, copper and iron are important ingredients, but the most expensive materials are ‘precious’ metals such as cobalt, nickel and manganese, along with elements such as graphite and lithium. These materials must be extracted or mined from the earth in a complicated and expensive way, which is one reason why electric vehicles are more expensive to buy than combustion cars. The costliest component of an EV is its battery. 

What challenges are Battery Manufacturers facing? 

There are many challenges facing battering manufacturers today. First and foremost, there is an increasing demand for battery design and production to be sustainable. A key driver of the introduction and uptake of electric vehicles is the need to better care for and protect our planet. This has had a real impact on both consumer buying behaviours, with more people considering the environmental impact of their purchases, and the expectation and responsibility placed on businesses to do their part. This extends to the battery manufacturing industry, now not only do they need to navigate new technologies, but they must do so in a sustainable way.  

Further to this, manufacturers must also meet the steadily growing quality requirements, while also juggling the need to reduce costs and beat the competition. Users are demanding higher capacity, better quality, more safety and a longer service life for batteries, as well as the ability to drive longer trips without having to recharge electric vehicles. This is something manufacturers need to keep in mind. 

Industry-leading Solutions to help you overcome these challenges and drive success 

End-to-end Battery Design, Development, and Delivery with 3DEXPERIENCE 

  • Design, develop, and deliver battery innovations, from chemistry to system all within a single, collaborative environment. Find out more in our webinar.
  • Discover how leveraging virtual twin technology can help you to visualize real-life battery behaviors through a digital replica of a physical battery system. Find out more in our webinar.
  • Explore how advanced simulation can help you overcome aerodynamic challenges to increase battery range and performance. Find out more in our webinar.
Are you looking to power up your battery design and development? Get in touch with our team today.