As the demand for electric vehicles (EVs) continues to rise, driven by global initiatives to reduce carbon emissions, the need to improve battery production efficiency has never been greater.
In July 2024, one in seven vehicles sold globally was fully electric according to the AutoMotive’s Global Electric Vehicle Tracker (GEVT). However, the UK EV market is described as “sluggish”, particularly for private buyers. Costs are often cited as the issue, as well as the faster depreciation of EV vehicles and the expense of battery replacement. In fact, research has found that 61% of consumers need to be sure that a battery will last before even considering an EV.
In today’s automotive market, battery expenses account for 30% to 40% of the total cost of an EV. Reducing this cost is critical not only for making EVs more affordable but also for ensuring their competitiveness against traditional gas-powered vehicles. As such, simulation technologies are proving to be a key driver in achieving these cost reductions by streamlining the battery manufacturing process, improving efficiency, and enabling the development of safer, more durable batteries.
Simulation’s role in reducing EV battery costs
The EV industry is actively seeking ways to reduce battery prices, which are projected to drop by 40% by 2025. One approach involves simplifying packaging and making more strategic material choices; for instance, using silicon in place of traditional materials can enhance energy density and reduce charging times. Yet, traditional manufacturing methods are not always sufficient to optimise these processes, and without clear methodologies, manufacturers may continue to struggle with inefficiencies and sustainability challenges.
Simulation offers a way to overcome these obstacles. By simulating various aspects of the production process, manufacturers can significantly reduce trial-and-error experiments and optimise operations. This virtual testing environment allows manufacturers to predict the outcomes of different design and process adjustments, saving both time and resources.
Battery manufacturers around the globe are increasingly turning to simulation to meet customer specifications, reduce costs, and maintain high quality standards. Simulation tools also play a critical role in addressing labour shortages, ensuring safety and compliance, and improving the disposal and recycling processes for batteries at the end of their life cycle.
Optimising production with multiphysics simulation
In the highly complex field of battery manufacturing, the ability to test processes and materials virtually is invaluable. For example, during the electrode coating process, the application of fluid dynamics simulation allows manufacturers to evaluate various conditions and geometries of the coater. Similarly, the calendaring process—where battery components are compacted—can be optimised through particle dynamics simulations. This step is critical in influencing the performance of lithium-ion batteries by refining the pore structure. These insights are essential for addressing imperfections and ensuring consistent quality.
Simulation can also identify residual strains during the manufacturing process, offering manufacturers an opportunity to address potential weak points before they become costly issues in mass production. These capabilities underscore the importance of integrating simulation into the battery manufacturing process, particularly as manufacturers strive to meet the increasing demands of the EV market.
The rise of digital twins in battery manufacturing
A major trend in battery production is the use of digital twin technology to digitise and streamline operations. A digital twin is a virtual representation of a physical process, created using real-world data from sensors and simulation models. By leveraging these digital counterparts, manufacturers can optimise entire production lines and predict potential failures, thus reducing downtime and maintenance costs.
Digital twin technology is particularly powerful when combined with predictive analytics. By feeding simulation data into an analytics engine, manufacturers can accelerate the development of predictive maintenance models, identifying potential issues before they occur. This proactive approach can significantly reduce the time required for data collection and improve the overall reliability of production processes.
Solid-state battery manufacturing
The search for alternatives to lithium-ion batteries is driving interest in solid-state batteries, which offer the potential for improved safety, higher energy density, and a more flexible design.
Simulation plays a crucial role in advancing solid-state battery technology. By modelling processes such as particle size distribution, material mixing ratios, and compaction pressure, manufacturers can identify optimal configurations before physical prototypes are built. This reduces both the time and cost associated with developing this next-generation battery technology.
A path forward for the EV battery industry
The use of advanced simulation technologies is transforming the EV battery manufacturing landscape. From optimising production processes to predicting maintenance needs, these tools are enabling manufacturers to meet the challenges of the growing EV market head-on. The ability to simulate and test different scenarios virtually not only improves efficiency but also enhances sustainability, safety, and overall product quality.
As the automotive industry continues its transition to electrification, the role of simulation in battery production will only grow in importance. Manufacturers who embrace these technologies will be better positioned to meet consumer demand while driving down costs and maintaining the high standards required for a competitive EV market.
About the Author
Akira Fujii is principal application engineer at Ansys. For more than 50 years, Ansys software has enabled innovators across industries to push boundaries with the predictive power of simulation. From sustainable transportation and advanced semiconductors, to satellite systems and life-saving medical devices, the next great leaps in human advancement will be powered by Ansys.
