AI speeds up development of structural EV batteries in German study

Scientists at RWTH Aachen University in Germany have accelerated the development of structural electric vehicle (EV) battery systems by combining advanced engineering with AI-driven validation techniques. Over three and a half years, the PEAk-Bat research project, funded by the German Federal Ministry for Economic Affairs and Energy, demonstrated that integrating batteries directly into the vehicle chassis—rather than treating them as separate components—can increase volumetric energy density by over 10% and gravimetric energy density by more than 15%. The project involved building and rigorously testing 10 vehicle prototypes with integrated structural battery systems, supported by extensive digital simulations validated through real-world trials. A key innovation of the project was the use of AI-powered simulation models for early validation of battery safety, structural integrity, and thermal performance. This virtual-first approach significantly reduced the need for time-consuming and costly physical tests, enabling faster development cycles and lower prototype costs. The researchers also developed new industry guidelines for analyzing changes in battery systems and determining necessary safety tests