Simulation App Speeds Up Electric Truck Battery Design

The push for sustainable transportation has led to significant investment in electric trucks, yet their widespread adoption has been hampered by limitations in battery lifetime, especially for long-distance highway travel. This challenge is being addressed through innovative computational modeling and simulation, which are proving instrumental in refining battery design and manufacturing processes.

LaserBATMAN

The "Multiscale Simulation of Laser Welding for Optimal Battery Pack Manufacturing" project, known as LaserBATMAN, was a three-year initiative concluding in May 2025. Its primary objective was to enhance two critical performance metrics for battery packs: robustness and lifetime. A key focus of the project was the laser welding process, which is vital for joining battery components like cells and busbars.

Incorrect laser welding can lead to accelerated battery degradation, while precise execution can significantly extend battery life. The LaserBATMAN project leveraged computational modeling to understand and optimize this intricate process, ensuring that the manufacturing techniques contribute positively to the overall durability and performance of the battery packs. This detailed approach to a specific manufacturing step underscores the complexity and precision required in advanced battery development.

COMSOL

Central to the LaserBATMAN project's success was the application of COMSOL-based multiscale simulation and a custom simulation app. This sophisticated software allowed the consortium to model the intricate physics involved in laser welding, from the micro-level interactions to the macro-level impact on the entire battery pack. The custom app, developed by Resolvent, a Denmark-based engineering consultancy, provided Volvo's R&D department with an accessible tool to test battery lifetime performance efficiently.

By simplifying complex simulation workflows into an intuitive application, engineers at Volvo could rapidly iterate on designs and manufacturing parameters without needing deep expertise in the underlying simulation software. This democratization of advanced simulation capabilities is a significant step forward, enabling faster design cycles and more thorough testing of various scenarios. The ability to quickly assess the impact of different welding parameters on battery longevity is crucial for optimizing performance and reliability.

Volvo Group Trucks Operations

Volvo Group Trucks Operations was a key industry partner in the consortium, which also included Aurobay, Resolvent, the European Commission, the Technical University of Denmark (DTU), and Vinnova. Volvo's involvement highlights the direct industry need for such advancements, as they are at the forefront of developing electric trucks for commercial fleets. The insights gained from the LaserBATMAN project directly feed into their product development, aiming to produce more robust and longer-lasting batteries.

This collaboration between academia and industry is vital for translating cutting-edge research into practical applications that can drive real-world change. By improving the robustness and lifetime of batteries, Volvo can offer more reliable and economically viable electric trucks, thereby accelerating the transition to electric heavy-duty fleets. This not only reduces fuel and maintenance costs for companies but also significantly lowers carbon emissions, contributing to broader environmental sustainability goals.