The RESiLiTE (Robust, Economical, Silicon-rich, Lightweight and Thermally Efficient Battery Packs) project, an initiative co-funded by Horizon Europe, the European Union’s primary funding program for research and innovation, has successfully completed its first year of project implementation.
Through the joint efforts of RESiLiTE partners, the project has moved closer to its final goal to integrate large format cylindrical cells within a novel thermoplastic battery housing, aiming to increase the energy density, energy efficiency, operating temperature range, fire safety and sustainability of future battery packs.
During the first year of project implementation, the consortium completed the battery pack requirements and architecture milestone, defining the reference architecture for a lightweight Cell-to-Pack battery system based on large-format cylindrical cells. This included the definition of key system requirements, battery pack architecture, vehicle integration interfaces, thermal management architecture and benchmarking methodologies, establishing the technical baseline for subsequent design, simulation and validation activities throughout the project.
The consortium developed an integrated battery enclosure concept combining lightweight thermoplastic structures, structurally functional cell holders and an integrated cooling system. By coupling system requirements with simulation-based development from an early stage, the project established the foundation for integrated engineering across thermal management, cell-to-pack integration and safety development. Initial mechanical and thermal simulations confirmed the feasibility of the concept, enabling efficient design iterations and supporting the transition toward detailed design, prototype development and future validation activities.
Significant progress was achieved in the development of advanced diagnostics and battery management system (BMS) functionalities. The consortium established methodologies based on electrochemical impedance spectroscopy (EIS) and model-based SoX estimation to improve the assessment of battery condition and enable early detection of degradation mechanisms and safety-relevant phenomena such as lithium plating. These developments provide the basis for the implementation and validation of advanced BMS functions in the next project phases.
Sustainability and circularity considerations were also integrated into the technical development workflow from the outset. During the first project year, the consortium established a framework for lifecycle assessment, circular design strategies and recyclability evaluation. The related activities are ongoing and will support the consideration of environmental impact, recyclability and second-life potential throughout the design process.
Next year of implementation
During the second year of the RESiLiTE project, work will progress from system definition to detailed design, prototyping and validation. The focus will shift to the mechanical and thermal design of the battery enclosure, integration of advanced cooling and safety concepts, and implementation and validation of BMS functions.
Work will also progress on manufacturing readiness, including tooling and prototype production, alongside experimental validation through multilevel testing and benchmarking. This phase will support evaluation of the solutions under realistic conditions and further development toward higher technology readiness levels (TRLs) and potential industrial deployment.
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