The original hybrid battery cells used in the P1 were manufactured in 2010. After 16 years of service, numerous units have deteriorated to the point that they must be replaced, otherwise the car will be undriveable.

Project Continuum from V Engineering offers current and future McLaren P1 owners an alternative high-voltage battery solution that improves energy storage and reduces the overall weight of the original battery with no penalty to the existing power delivery. Another key user feature of the new battery is that it offers extended EV range compared with the factory production unit.

Developed in collaboration with engineers involved in the original P1 program, the battery features a glycol-based cooling system with significantly improved heat rejection properties from the newly developed cells. The battery solution is built around a proven, high-performance 21700 lithium battery module engineered to FIA Formula E requirements to offer motorsport-grade technology. The plug-and-play approach from V Engineering reportedly improves performance and reliability while retaining compatibility with the vehicle’s existing electrical architecture.

Along with the advanced cooling properties of the new battery, design also focused on the energy storage capacity of the new unit, which has been increased to 12.4kWh compared with the standard 4.72kWh of the original P1.

Customer installations are scheduled to begin in spring 2027, with V Engineering currently in discussions with owners from the UK and Europe, the Middle East and the USA.

Project Continuum is the first phase of a broader powertrain development program intended to provide long-term technical support for McLaren P1 owners.

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To address these challenges, Göpel Electronic has developed a high-performance, quickly configurable battery cell tester that features a modular design and high flexibility. This allows for the quick and transparent determination of quality, charging efficiency and reliability in up to five battery cells simultaneously. The tester complements the product portfolio, which includes, among other things, Göpel Electronic’s EOL battery test system, which performs comprehensive test routines for the entire battery pack.

The battery cell tester covers standard safety tests that evaluate the condition of the cells. The open circuit voltage (OCV) value indicates the voltage of a battery without a load (open circuit) and serves as an indicator of its state of charge. For the alternating current internal resistance (ACIR) measurement, the tester uses a method to determine the internal resistance of the battery cells. This internal resistance under alternating current provides information about the performance, state of aging and quality of the battery cell.

According to Göpel Electronic, its tester delivers fast, repeatable results and can be integrated with automated equipment to enable high-throughput batch testing within seconds. The system is designed for applications including incoming inspection and battery cell grouping.

In related news, CamMotive and Thermulon join £2m Drive35 project to improve EV battery safety

The companies will collaborate with a leading UK OEM to tackle the issue of thermal runaway (TR) in EV battery systems.

TR is a significant challenge in EV technology. Lithium-ion battery cells used in EVs can, under certain fault conditions, heat uncontrollably, creating a thermal chain reaction that may propagate across a module or battery pack and potentially lead to fire or explosion. Global regulators and manufacturers are increasingly strengthening safety expectations for battery technologies in response to growing awareness of the issue.

The 12-month UK collaboration will develop and evaluate AeroMotive, a UK-made aerogel-based EV thermal runaway barrier solution being developed for use in next-gen battery systems. The technology uses thin, lightweight layers of highly insulating anti-thermal propagation (ATP) material to limit heat transfer between cells and mitigate the propagation of TR.

CamMotive will design a testing and validation program to evaluate the solution’s performance under various conditions. This includes specialist prismatic cell swelling and compression testing to analyze the impact of forces on battery cell longevity and safety and optimize the performance of the ATP pads.

Luke Barron, senior engineer at Cambridge-based CamMotive, said, “This ground-breaking project will deliver critical research and testing methodologies that make EV batteries safer. By advancing UK innovation in battery technology, we’re helping to accelerate the transition to safer, cleaner, high-performance electric vehicles.”

The project is supported by the UK government’s £4bn (US$5.4bn) Drive35 program, delivered by the Department for Business and Trade in partnership with the Advanced Propulsion Centre and Innovate UK.

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The BQ79826Z-Q1 battery monitor enhances safety and extends battery life by detecting potential failures from within battery cells. The single chip tracks up to 44% more channels than previous generations. With this increase, the device significantly decreases the number of components required in a battery pack, reducing system complexity and cost without compromising reliability

“The electrification of transportation and the rapid expansion of energy storage are redefining what battery performance must deliver, and as a leader in battery management technology, TI is uniquely positioned to meet that challenge,” said Wenjia Liu, vice president and general manager, battery management systems (BMS) at TI.

“Our high-cell-count battery monitor with a built-in EIS engine helps ‘shine a light’ inside battery cells, delivering rich chemical-state data that enables systems’ software to make informed, real-time decisions on safety and performance of the battery pack, allowing engineers to address the most critical challenges in battery management.”

Delivering safety and performance with EIS technology 

EIS monitors a battery and delivers continuous, real-time insight that reveals the battery’s health and warns of issues before they become critical. Integrated EIS technology enables the BQ78926Z-Q1 to detect fault conditions earlier – from inside the cells – helping maintain safety and notifying passengers of potential vehicle hazards such as thermal runaway.

Maximizing efficiency with industry-leading cell count

According to the company, the BQ79826Z-Q1 supports up to 26 cells per device – eight more than competing solutions. By reducing the number of monitoring devices required, it lowers bill-of-materials costs, simplifies system architecture and minimizes board space requirements, delivering significant cost savings per channel without compromising quality or reliability.

When paired with the BQ79881-Q1 pack monitor and optional TI communications bridge, these devices create a powerful chipset that works across different module sizes, battery chemistries and mechanical designs, giving engineers the flexibility to design once and deploy everywhere.

Calculating charge readings with the best-in-class accuracy

With a voltage accuracy of <2mV across a full temperature range of –40°C to +125°C, higher resolution analog-to-digital converters and ultra-low noise, the BQ78926Z-Q1 enables more accurate state-of-charge calculations, directly addressing one of the biggest concerns for EV drivers: range anxiety.

Using EIS technology, this device enables more accurate temperature and state-of-charge estimation, helping designers achieve longer battery life and faster charging without compromising battery health.

With an EIS measurement time that is five times faster than previous solutions, this device delivers the highest functional safety voltage reading per cell. Compliance with Automotive Safety Integrity Level D and International Organization for Standardization 26262 gives designers a smarter, more efficient path to safer, longer-lasting batteries.

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The collaborative program set out to anticipate the safety behaviors of solid-state battery cells under increasingly demanding operational and regulatory conditions, and address technology-specific requirements, including pressure management and mechanical integrity at the cell and system levels.

The initiative combined Blue Solutions’ battery cell technology and AVL’s expertise in battery simulation, validation and safety assessment. Conducted on a non-exclusive basis, the collaboration allowed both partners to strengthen their programs while continuing to support broader industry progress.

Anticipating safety at scale

As battery technologies evolve toward higher performance and higher volumetric energy density, the joint program confirmed that safety can be embedded early in the design process.

The work focused on predictive safety simulations during cell technology scale-up, and evaluated technology-specific behaviors, including internal pressure management. Advanced abuse and failure scenario modeling, and alignment with emerging safety regulations, were also studied.

Toward thermal-propagation-free battery systems

The program also addressed thermal propagation (TP). By combining advanced modeling, pressure-aware design and safety-first architecture, the partners demonstrated pathways toward eliminating thermal propagation risks.

Simulation-based and validation test results demonstrated positive and consistent outcomes, including compliance even under the latest New Energy Vehicle regulations. The technology meets the GB 38031-2025 requirements.

The program confirmed that the intrinsically high volumetric energy density of Blue Solutions’ technology is safeguarded, while maintaining robust safety margins. Results demonstrated targets of up to 25% higher volumetric energy density compared with equivalent NMC Li-ion battery packs, alongside an expected 13% increase in gravimetric energy density.

Results and key lessons learned will be disseminated at leading international conferences and battery industry events.

“We are very happy to have collaborated with AVL,” said Olivier Caumont, battery systems director at Blue Solutions. “Their vision and mastery in multiple sectors, combined with our extensive manufacturing experience in solid-state battery manufacturing and pack integration, including the safety, thermal or mechanical aspects, have enabled us to confirm that our solution is fully aligned with market needs, and capable of fulfilling the most stringent safety requirements.”

“Working with Blue Solutions’ latest solid-state battery technology is a significant step forward for AVL,” added Paul Schiffbänker, director of battery development at AVL List. “It not only deepens our understanding of the specific safety characteristics of this next-generation chemistry but also actively drives the further development of our safety methodologies and battery design solutions. From advanced simulation-based prediction models to new validation and assessment approaches, this collaboration enables us to systematically embed safety into the development of future high-energy battery systems from the very beginning.”

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The test forms part of ongoing research into how multiple battery cells operate together within a complete pack, with a focus on energy density, thermal behavior and fast-charging capability in real-world conditions.

According to Donut Lab, the Verge TS Pro equipped with its battery technology charged in less than 10 minutes, making it “the world’s fastest charging electric motorcycle”, the company said.

“This is the first test we have published to a wider audience that demonstrates the performance and behavior of multiple battery cells in a real vehicle environment,” said Ville Piippo, CTO at Donut Lab. “The high energy density of our battery technology enables flexible battery pack design and superior performance even in more challenging applications, such as motorcycles, where space is limited and system simplicity is key. We are able to offer vehicle manufacturers packs with different energy capacities in the same physical size, with even the smallest packs having very high capacities.”

In the test, an 18kWh battery pack was charged using a public fast charger starting at approximately 20°C. The system reached a peak charging power of over 100 kW (around a 5C rate) for five minutes, with state-of-charge increasing from 10% to 50% in about five minutes. Overall, the motorcycle achieved a 10–70% charge in just over nine minutes, and 10–80% in approximately 12 minutes.

The solid-state-related battery architecture enables flexible pack design, enabling different energy capacities to be packaged within the same physical footprint, which is particularly relevant for space-constrained applications such as motorcycles.

“Our goal is to provide Verge users with the best possible user experience,” said Tuomo Lehtimäki, CEO of Verge Motorcycles. “The advantages of Donut Lab’s battery technology, such as ultra-fast charging, complement our goal seamlessly. The world’s fastest charging electric motorcycle, the Verge TS Pro, is also air-cooled. The battery pack used in this test is our standard model, but an extended range version is also available, with approximately two-thirds more energy capacity.”

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The lab’s high-current capability is designed to test large automotive cells and other high-power, high-capacity battery technologies, including those used in eVTOLs, data centers and stationary battery energy storage systems (BESS). Its extensive channel count is useful to companies with high-volume testing requirements, enabling hundreds of cells to be tested simultaneously under varying conditions. High-precision cyclers and advanced EIS tests also enable accurate long-term analysis and performance characterization, including cell ageing and end-of-life simulation, with modeling and calibration expertise provided by CamMotive’s specialist engineers.

The facility offers additional technical capability and services, including dynamic climatic chambers to replicate varying temperature conditions, and process thermostats for real-world thermal management testing. For high-power module and pack testing, the lab provides capability up to 1MW.

The primary purpose of the new laboratory is to support automotive OEMs and accelerate development timelines by gathering data for modeling, compliance and improved understanding, leading to enhanced performance, longer useful life and faster charging strategies.

In addition to the main facility, the laboratory also houses several lower current cyclers for testing of smaller capacity cells. In this way, the company aims to support innovation in battery technology, including startups working on the latest chemistries and organizations exploring battery options for new applications.

Bruce Campbell, director at CamMotive, said, “The launch of our new test facility marks the latest phase of CamMotive’s commitment to advancing battery technology and its applications. We provide solutions across the entire battery ecosystem, from early concept to end-of-line validation.

“Working with UK cell developers and digital modelers, manufacturers and integrators, we combine world-class testing infrastructure with decades of powertrain expertise to help our partners deliver sustainable solutions for road, air, sea transportation and stationary applications.”

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The tests evaluated the Donut Battery’s charging speed and thermal behavior during charging. They simulated a worst-case scenario in which the battery cell lacks active temperature controls and its temperature can rise freely at extremely high charging rates.

The measurement was done using two passive cooling configurations. In the first, the cell was surrounded by two lightly compressed aluminum cooling plates; in the second, the cell was attached to only one bottom cooling plate. Recharging rates are indicated using C-rates, where 1C means the battery is charged from empty to full in one hour (5C = ~12 min, 11C = ~5-6 min). Traditional lithium-ion batteries typically charge at 1C to 3C with active cooling, whereas in this measurement the charging power rises to significantly higher rates without active cooling. The testing began with a standard discharge capacity test at 1C, which was followed by rapid charging tests (at 5C and 11C) with both cooling configurations.

The results are in line with the five-minute charging time previously announced by the company.

The measurements indicate that the Donut Battery can tolerate high charging rates without active temperature control. Under the specified test conditions, the cell was charged at 5C for more than nine minutes, reaching 80% state of charge in approximately 9.5 minutes and 100% in just over 12 minutes. Following discharge, the cell delivered 100% of the charged capacity.

The battery cell was then recharged rapidly at the extreme speed of 11C. Charging from 0-80% was achieved in 4.5 minutes and a full 100% state of charge in just over seven minutes. When discharged after a full charge, 98.4-99.6% of the battery capacity was available for use.

Even though the testing conditions did not directly simulate cell behavior in a battery pack, the testing demonstrates the benefits of the Donut Battery as part of a pack. The battery cell does not require any particular compressive force and works well with passive cooling, which simplifies the battery pack architecture.

“Unlike other solid-state batteries requiring high compressive pressures and undergoing volume changes of up to 15-20% during recharging cycles, the Donut Battery does not require special compression or more extensive cooling. This greatly simplifies the structure of battery packs and enables solutions that are cost-efficient, powerful and better than traditional lithium-ion batteries in terms of energy and power density,” said Donut Lab CTO Ville Piippo.

In related news, Integrals Power LMFP cells pass 1,500-cycle test milestone with strong durability and low-temperature performance

The ongoing test program has achieved more than 1,500 charge and discharge cycles at a 1C rate, with the pouch cell retaining nearly 80% of its original capacity. The 1,000-cycle milestone was passed last year, at which point the retained capacity was more than 80%. Durability is critical for lithium-ion battery packs in applications requiring long service life with minimal degradation, such as electric vehicles.

Sub-zero testing by Cranfield University evaluated the pouch cell’s ability to retain high capacity in extremely low temperatures. The tested cell, from the same batch as those evaluated by QinetiQ, retained 85% of capacity at -25ºC and 68% at -30ºC. In comparison, benchmark LFP and LMFP chemistries typically retain around 50% and 40%, respectively.

In addition to durability and performance, Integrals Power’s LMFP material offers lower cost, improved safety, reduced toxicity, less reliance on critical minerals and a smaller carbon footprint compared with nickel manganese cobalt (NMC) chemistries commonly used in EV batteries. It also provides higher energy density than LFP.

Integrals Power founder and CEO Behnam Hormozi said, “Independent, third-party testing by industry experts is a cornerstone of our business, and these latest results from QinetiQ and the University of Cranfield are invaluable in providing trusted and credible data to our customers around the world.

“The results prove that batteries made from our LMFP material can last longer, and perform better in sub-zero conditions. Overcoming the compromises and limitations imposed by existing cell chemistries is essential if battery power is to realize its full potential across a range of sectors, and we’re showing that it can do exactly that.”

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As electrification continues to transform the automotive sector, developers are under increasing pressure to validate systems that must operate reliably across a broad spectrum of conditions. The rapid expansion of electric mobility is driven by technological advances, global CO₂ reduction goals and supportive regulatory frameworks. Charging infrastructures are scaling, vehicle architectures are evolving, and OEMs are compressing development timelines. With this acceleration come engineering challenges that differ fundamentally from those of combustion engine platforms, ranging from high-voltage safety to the integration of complex power electronics.

At the center of these challenges lies thermal management. Batteries, power electronics and electric motors are highly sensitive to temperature fluctuations. Their efficiency, durability and safety depend on precisely regulated heat flows. Cabin climate control also becomes a strategic efficiency factor because electric vehicles do not generate waste heat from an internal combustion engine. Alternative heating concepts must therefore maintain comfort while preserving driving range. As a result, testing technology for thermal management components has become a pivotal enabler for innovation across the EV sector.

Poppe + Potthoff Maschinenbau, a Germany-based company, develops modular test benches designed to reproduce thermal and hydraulic conditions encountered in electric vehicle applications. The systems are built to support comprehensive testing methodologies that address efficiency, reliability and safety requirements. Integrated measurement and control technologies allow detailed analysis during development and validation processes.

The growing demand for robust thermal management testing

The shift toward electric vehicles has elevated thermal management to a defining performance factor. Batteries must remain within a narrow thermal window to ensure longevity and safety. Inverters and power electronics require cooling to maintain efficiency. High-performance traction motors generate significant heat during dynamic loads. At the same time, growing variability increases the overall validation workload. Each cooling circuit comes with its own media requirements and operating patterns that must be reproduced with high fidelity. Test systems therefore need not only faster reconfiguration but also precise calibration to the functional profile of each module. This reinforces the importance of modular test architectures capable of covering multiple cooling variants within a single infrastructure, thereby shortening development timelines and improving overall test efficiency.

Testing these systems under controlled conditions is crucial to validate long-term functionality. Components such as hose assemblies, valves, cooling plates, heat exchangers, electric pumps, pressure vessels and entire cooling loops must tolerate thousands of load cycles, temperature shifts and flow variations over the typical 10- to 15-year service life of an electric vehicle.

Poppe + Potthoff Maschinenbau’s portfolio addresses this need with dedicated solutions for dynamic pressure cycling, static pressure holding, flow measurement, burst pressure testing and functional testing of live components. These test benches replicate the thermal, mechanical and electrical stresses that occur during daily operation, enabling engineers to detect weak points early and optimize materials, joining processes and overall system architecture.

Dynamic pressure cycling: simulating lifetime stress in accelerated time

A central application is the simulation of pressure fluctuations in cooling and heating circuits. Components are placed inside the test chamber and exposed to load profiles that mirror real driving conditions. Depending on the system, the test medium is circulated at temperatures between -40°C and +140°C. Water-glycol mixtures such as Glysantin G40, G44 or G48 are commonly used.

Cooling circuits are tested between -40°C and +20°C, while heating circuits undergo thermal cycling from +20°C up to +140°C. Many components must withstand more than 100,000 load changes during their lifetime, and these conditions can be reproduced in the laboratory within only a few weeks. The system’s programmable pressure waveforms, either sinusoidal or trapezoidal, run at frequencies between 0.2Hz and 2Hz or higher. Flow rates range from 1 to 50 liters per minute at pressures between 0.2 and 12 bar or more. This level of control makes it possible to test plastics, metals, composites and sealing materials under consistent and reproducible conditions.

Test standards evolve continuously. Poppe + Potthoff test benches can be configured to meet specifications such as MBN 10306, VW 8000, GS 95024 3 1 and GMW 14193. Climate chamber integration enables combined environmental and functional stress testing, including tests with overpressure and underpressure, if required.

Identifying weak points and optimizing system design

Material transitions such as weld seams, press fits and adhesive bonds often represent sources of fatigue. By exposing components to realistic pressure and temperature cycles, engineers can identify early-stage cracking, swelling, deformation and leakage. These insights help refine design choices, improve production quality and stabilize system performance long before large-scale manufacturing begins. Throughout the test, inlet and outlet temperatures, flow rates, pressure drops, current and voltage for active components and ambient conditions are measured continuously. Thermal sensors placed on the test object highlight areas of energy loss or potential overheating, contributing valuable information for further optimization.

Accelerated durability testing for long-term reliability

Long-term tests generally run for 20 to 30 days, depending on the chosen load frequency. Ambient and media temperatures vary according to the test specification, and all key parameters are logged continuously. This accelerated method simulates several years of operation within a matter of weeks. It reveals aging behavior, degradation patterns and the effects of repeated thermal and mechanical stress on component performance. The data supports predictive maintenance approaches, extended warranty assessments and material qualification.

Functional testing under realistic electrical loads

Efficiency is a decisive performance factor in electric vehicles, since every watt drawn by thermal management components affects vehicle range. Poppe + Potthoff Maschinenbau therefore offers functional test benches that evaluate performance and energy consumption under low- and high-voltage conditions.

Cooling and heating units, control valves and pumps can be operated at voltages between 0 and 24V DC or up to 1,500V DC and 150A to simulate onboard battery or traction battery operation. Tests are carried out across a thermal spectrum from -40°C to +100°C, with optional climate chamber integration extending the ambient range to +140°C. Comparing measurements before and after a durability test shows how components degrade over time. These insights are essential for planning service intervals, improving efficiency and safeguarding long-term system stability.

Safety, usability and digital integration

Safety is an integral part of every system. Test chambers are built from welded stainless steel and equipped with high-strength laminated safety glass. A closed medium circuit prevents the formation of hazardous vapors. Operation is streamlined through recipe management, which enables predefined test sequences to be selected via PC or handheld scanner. National Instruments’ LabView platform provides comprehensive data visualization and acquisition. All test data is stored automatically and can be exported for further analysis. The open software architecture makes it possible to integrate additional sensors and custom data channels whenever needed.

Enabling the next generation of electric mobility

As electrification advances, precise and adaptable testing solutions are essential for validating new concepts and ensuring safe, efficient and durable electric vehicles. By reproducing the interaction of temperature, pressure, flow and electrical load, the test setups provide engineers with data that can support the design and assessment of components across the full service life of an electric vehicle. This contributes to a more detailed understanding of thermal management behavior within modern electric mobility.