The call follows recent high-profile electric vehicle battery recalls affecting thousands of cars in the UK, highlighting the growing challenge of managing lithium-ion battery safety as electrification accelerates across transportation sectors.

BatteryIQ’s innovative battery management systems can detect abnormal behaviors at the individual vehicle level, enabling targeted intervention instead of fleet-wide action.

“Car manufacturers could avoid major recalls caused by suspected battery issues,” said Nick Bailey, founder of BatteryIQ. “Innovative battery management systems created by BatteryIQ can pinpoint abnormal behaviors in a specific vehicle or a small group of vehicles. In many cases, this means issues can be addressed early, sometimes even via software update, without the need to recall entire fleets.”

The company says the lithium-ion industry is moving from reactive safety, responding after faults emerge, toward predictive monitoring that continuously tracks battery health in real-world use.

Its innovative battery management systems embed intelligent monitoring within the battery system, analysing cell behaviors, degradation patterns and operating conditions in real time to identify early warning signs of failure, damage or misuse.

“Battery-health monitoring is effectively the equivalent of having a smoke alarm inside a battery system,” Bailey explained. “It provides early warning of stress, degradation or abnormal cell behaviors long before a dangerous condition develops.

“The next step for the industry has to be the universal adoption of connected battery-health monitoring. Manufacturers, operators and users should receive alerts well before a battery reaches a critical or unsafe state.”

The company says this shift would enable earlier detection of defective or degrading batteries, enabling targeted servicing or software intervention before problems escalate. It could also reduce fire risks and safety incidents, lower warranty and recall costs, and increase confidence among insurers and regulators, supporting the safer adoption of electrified transportation.

Tanya Sinclair, CEO, Electric Vehicles UK, said, “Electrification isn’t just about selling vehicles; it’s about creating a mature, resilient ecosystem around them. Connected battery-health monitoring is exactly the kind of smart, preventative technology that builds confidence across the system: for drivers, manufacturers, insurers and regulators alike. It also creates efficiencies not possible with combustion cars.”

Related news, Renault Ampere partners with Basquevolt to advance lithium metal-based EV battery technology

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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, Donut Lab brings solid-state battery to market

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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.”

Related news, Changan and CATL launch world’s first mass-production sodium-ion EV

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“Hyundai Motor is reducing carbon emissions by working with global partners to deploy hydrogen fuel cell trucks across various sectors such as logistics, distribution and urban public operations,” said Chul Youn Park, head of the global commercial vehicle and light commercial vehicle business division at Hyundai Motor Company. “Starting with our initial operations in Switzerland, we have expanded our presence across multiple regions in Europe while achieving visible progress in North America as well. Our hydrogen commercial vehicles continue to demonstrate their value as mobility solutions for a more advanced future, helping build the hydrogen ecosystem and expanding their global impact.”

Hydrogen mobility

First launched in Switzerland in October 2020, Xcient Fuel Cell trucks initially reached 10,000,000km of cumulative driving distance in the country by June 2024. The trucks’ consistent performance has spurred expansion into new regions and a growing range of applications, including food and beverage logistics, supermarket distribution and specialized vehicle types such as refuse and crane trucks.

Compared with a fleet of conventional diesel trucks, which would emit around 13,000 tons of CO2 over 20,000,000km, Hyundai’s Xcient Fuel Cell trucks achieve a substantial reduction in carbon emissions – roughly equivalent to the annual CO2 absorption of 1.5 million pine trees.

Hyundai Motor launched the new Xcient Fuel Cell truck in 2025, with an upgraded hydrogen fuel cell system. The vehicle has undergone rigorous testing since 2021, ensuring its suitability across a range of climates and use cases. This testing, combined with continuous collaboration with fleet operators, has ensured the vehicle meets various customer driving needs.

In related news, Kia EV2 prototype demonstrates “impressive range” in extreme cold tests

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The group is expanding its services to include vehicle-to-grid (V2G) capabilities in Korea and Europe, as well as vehicle-to-home (V2H) services in the US.

“V2G services are expected to provide EV customers with a new mobility experience related to their energy life,” said Hokeun Chung, executive vice president of future strategy division at Hyundai Motor Group. “Through the domestic and overseas V2G services, we aim to strengthen the competitiveness of EVs while also playing a pivotal role in leading the eco-friendly mobility market and future energy market.”

Leveraging EVs as flexible grid resources

In Korea, the group will launch the nation’s first V2G pilot service in Jeju Island by the end of 2025, using the Kia EV9 and Hyundai Ioniq 9. The initiative aims to tackle Jeju’s renewable-energy surplus by using electric vehicles as flexible grid resources capable of returning stored electricity to the system.

Hyundai Motor Group, as the project lead, will overseess the technology verification of V2G and manage the overall operation, while the Jeju Special Self-Governing Province will support regulatory and policy improvements essential for implementation. Korea Electric Power Corporation (KEPCO) will facilitate the integration of EVs into the distribution grid, and Hyundai Engineering will focus on analyzing charging station operations and exploring future service enhancements.

Participants will be able to charge their EVs when energy prices are low and discharge electricity when prices rise through Jeju’s real-time energy market, supporting grid stability while helping reduce overall energy costs. Following the pilot phase, the group plans to expand V2G services nationwide in cooperation with government and municipal partners.

V2G in Europe

In Europe, Hyundai Motor Group is expanding its customer-centric energy solutions by introducing a commercialized V2G service in the Netherlands. As the first OEM to launch a customer-focused V2G service, the group is building on the smart charging (V1G) service introduced earlier this year. Customer recruitment for the V2G service will begin at the end of 2025.

The V2G service will use bidirectional chargers compatible with Hyundai and Kia vehicles. Customers on utility tariff plans will be able to automate charging during low-rate periods and sell surplus energy back to the grid at peak times, reducing electricity costs while creating new opportunities in energy trading.

Initially, this service will also be available only for the Kia EV9 and Hyundai Ioniq 9, but there are plans to expand coverage to other EV models. The group also aims to roll out the V2G service to other European countries, further advancing customer convenience and supporting the region’s transition toward smarter energy systems.

V2H service in the US

In the US, the group will launch its vehicle-to-home services in the near term, enabling EVs to provide energy solutions during natural disasters such as large wildfires, routine power outages and peak-demand periods.

Kia’s V2H service, launched in February 2025, enables EV9 owners to use their vehicles as reliable household backup power. Hyundai Motor will roll out V2H for the Ioniq 9, while Kia plans to extend the service to the EV6.

In related news, Polestar turns the Polestar 3 into a power source with bi-directional charging

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Super-fast-charging cylindrical packs contend with heat accumulation during high current/voltage in charging and discharging with high C-rate. XD Thermal’s side liquid-cooling concept routes serpentine tubes along the cell sidewall, increasing effective contact area versus bottom cooling plates. The enlarged vertical contact surface well resolved the challenge of heat gradients in Z-axial direction and eventually enables each individual cell to stay in a much more balanced temperature range, which is considered as a positive factor to maintain a longer life for Li-ion batteries.

XD Thermal has developed a family platform of side-cooled modules and packs built around robust structures and reliable quality assurance methods. Cooling tubes are pitched to match cylindrical cell layouts and can be combined flexibly with different manifolds, brackets and pipelines, while validated flow-path structures and internal design rules keep heat-transfer performance predictable from prototype to mass production.

“Platformized design reduces development cost and time and supports agile development for our customers,” said Guo, a technical engineer at XD Thermal. “With proven solutions of pipeline connections, electrical insulation and geometric combinations, we helped many customers complete side-cooled battery development smoothly.”

“Ramp-up and industrialization matters as much important as product development,” said Sun, head of manufacturing engineering at XD Thermal. In 2024, the company commissioned high-volume serpentine-tube lines with a daily capacity of 30,000 pieces, integrating automated forming, welding, cleaning and 100% leak testing.

“We provide a repeatable, scalable production system with confirmed development roadmap and SOP schedule, giving us proven capability for production ramp-up and line expansion. Normally, production line and toolings preparation could be finished 6-8 weeks before PPAP,” added Sun.

In related news, GAC begins local EV production at Magna’s European plant

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Michael Lohscheller, the Polestar CEO, said, “Bi-directional charging is a game-changer, not only for the car industry but also for the home energy ecosystem. As it lowers your total cost of ownership and makes your car work for you even when parked, this makes the choice of driving a Polestar even more attractive.”

Bi-directional charging technology enables electric cars to charge and discharge energy from their batteries. This initial bi-directional charging solution uses direct current (DC) and enables V2H functionality for Polestar 3 customers on the 400V electrical architecture. The offer targets California residents eligible for state incentives and includes Dcbel’s Ara home energy system. It enables customers to lower charging costs by up to US$1,300 per year and use their vehicles as a backup power source during outages for up to 10 days.

Olivier Loedel, head of software product management at Polestar, added, “We are very excited to deliver this initial bi-directional charging offer together with our North American partner, Dcbel. It’s a new technology that requires a sophisticated and intelligent ecosystem, and this marks an important first step as we aim to launch bi-directional charging features to more Polestar customers in more markets.”

In related news, Infineon and Munich Electrification partner to advance high-voltage battery management systems

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The test was completed independently by Lotus Alghanim in Kuwait and used Lotus’s ultra-fast 450kW DC charger. The car was able to maximize nearly the full capacity of the charger, reaching a peak charging power of 443kW, enabling it to charge from 10% to 80% in 13 minutes 35 seconds. This was achieved in extreme heat conditions in the region.

Emeya features a cell-to-pack battery structure, which means that 20% more cells can be packaged in the same space compared with a standard module architecture. It also uses a cooling system architecture that is designed to improve the thermal performance and efficiency of the battery.

The car has an 800V charging system, which is designed to deliver rapid charging and greater efficiency for drivers, no matter the charger they are using.

With a WLTC energy consumption down to 18.7kWh/100km, Emeya delivers up to 310km of range in 10 minutes. Additionally, the Emeya 2026 model year features a WTLP range of up to 610km.

Lotus has begun rolling out its ultra-fast 450kW DC charger in Europe, starting in Germany and followed by other European markets in the near future.

In related news, Toyota reveals ninth-gen Hilux pickup with BEV model

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The microcontroller combines precision, safety and programmability, while supporting zonal architectures and the transition to software-defined vehicles. To maximize its impact, Infineon is partnering with Munich Electrification, a leading provider of innovative battery management software. Together, they deliver advanced and cost-efficient battery management system solutions that accelerate development and reduce costs.

The PSOC 4 HVPA-SPM 1.0 offers a fully integrated design with key features that bring advanced intelligence, safety and efficiency to BMS. It provides high-precision monitoring of current, voltage and temperature, ensuring reliable battery performance and improving the accuracy of state-of-charge (SoC) and state-of-health (SoH).

Fully compliant with ASIL D (ISO 26262) safety standards, the microcontroller ensures robust and reliable operation in critical high-voltage battery systems. Its built-in Arm Cortex-M0+ processor delivers advanced edge intelligence, enabling faster data processing and reducing the load on the central ECU. This supports zonal architectures and enables original equipment manufacturers to customize the system for specific requirements, leading to shorter development cycles and faster time-to-market.

“The PSOC 4 HVPA-SPM 1.0 represents a significant leap forward in high-voltage battery management, combining precision, intelligence, and safety for next-generation electric vehicles,” said Ralf Koedel, vice president of automotive microcontrollers at Infineon. “The positive feedback from our first customers reinforces its value in enabling innovative and reliable solutions for electrified mobility.”

Infineon is expanding on the launch of the PSOC 4 HVPA-SPM 1.0 by partnering with Munich Electrification to deliver Smart Edge BMS Software for more intelligent and efficient battery management. The collaboration combines Infineon’s semiconductor technology with Munich Electrification’s expertise in battery software and system optimization to enable seamless integration and improved functionality. The joint solution is designed to cut cost and complexity while accelerating safe development of next-generation electric vehicles, helping OEMs meet regulatory requirements and advance sustainable e-mobility.

“We are extremely excited to contribute with our deep BMS and software expertise to the next level of cutting-edge technology in this partnership with the global leader in automotive semiconductors,” said Dr Uwe Wiedemann, managing director of Munich Electrification.

In related news, Ansible Motion and IAAPS partner on complete vehicle-in-the-loop test environment

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Its vision includes the latest addition to the Core diesel engine family, the 8‑liter, 252kW Core80; the Agco Power CO₂ Calculator concept; cost-effective remanufactured engines that extend machine lifespans while reducing environmental impact; and a 150kWh in‑house-developed Future Battery Concept.

“We believe the future of agricultural energy lies in a smart combination of fuels and technologies. There is no single solution – rather, a wider spectrum of power sources is needed. That’s why we are committed to exploring a wide range of innovations, investing significantly in R&D and our Clean Energy Lab, and promoting collaboration across the industry,” said Juha Tervala, vice president and managing director of Agco Power.

Battery concept

Agco Power’s Future Battery Concept is its latest product development project. It is based on NMC cell chemistry and offers 150kWh of capacity.

The company says it is tracking advances in battery cell technology and evaluating multiple chemistries, including solid‑state batteries. Hydrogen is also being investigated for energy storage. However, according to director of product development Kari Aaltonen, battery technology currently appears promising for agricultural applications due to the significant energy losses in hydrogen production and in the conversion of energy to electricity via fuel cells.

“Today, the best way for a farmer to achieve emission‑free operation is with a battery‑electric driveline,” said Aaltonen. “Most regular farm work can, in the future, be completed with a tractor equipped with this battery. The challenge will be very long working days, but high‑power DC charging will enable operators to resume work in around 40 minutes.”

Aaltonen estimates that powertrains based on the concept battery could reach production in 5-7 years. The Future Battery Concept is due to make its premiere next month.

Powering the Fendt 800 Vario Gen5

The latest member of Agco’s modern Core diesel engine family, the 8‑liter Core80, powers the Fendt 800 Vario Gen5, and delivers even more torque (1680Nm) and power (252kW) than other members in the Core family.

“The combination of power and low fuel consumption makes it possible for farmers to work economically while protecting the environment,” said Roland Schmidt, vice president, Fendt Marketing.

CO2 Calculator concept with Valtra

In collaboration with Valtra, Agco Power has developed the CO₂ Calculator concept – a solution that detects the type of fuel used and calculates the operational carbon footprint of agricultural machinery. It combines an engine-mounted fuel sensor with a cloud-based software solution that calculates accurate CO₂ emissions in real time. The visualized and stored data enables farmers to present verified figures to customers and supply chain partners.

“Reliable data on the operational carbon footprint is a major competitive advantage for farmers. It enables more informed decisions and allows them to track, visualize and verify their environmental impact,” commented Jarno Ratia, director of product management of Agco Power.

Agco’s technology solutions will be on display at Agritechnica 2025 in Hanover, Germany, in November.

In related news, H2Accelerate calls for equal classification of H2 -ICEs with other zero-emission technologies across Europe

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