In the fast-evolving energy sector, time is a critical factor, especially in battery development. Delays in testing can stall electrification efforts in industries and lead to the abandonment of promising green technologies. As Europe aims to enhance its energy independence and reduce emissions, accelerating the validation of battery technologies has become essential.
Billy Wu, an Associate Professor at Imperial College London, points out that every new battery design must undergo extensive testing under various conditions to assess performance, safety, and longevity. Unfortunately, the lengthy validation process—often lasting up to ten years—can prevent innovative batteries from reaching the market. Wu emphasizes that many viable concepts fail not due to technical shortcomings, but because the testing period is prohibitively long.
China currently outpaces Europe in battery innovation, where designs move from concept to deployment in just a few years. Wu notes that the Asian battery ecosystem supports rapid iteration and production, giving it a competitive edge.
To address this urgency, the EU-funded project THOR, led by Lise Daniel of the French Alternative Energies and Atomic Energy Commission (CEA), aims to reduce battery testing times significantly. The project is developing a digital twin technology to simulate battery behavior in real time, focusing on performance, safety, and lifespan. According to Daniel, relying solely on physical tests can extend development timelines by up to ten years. THOR seeks to cut this duration by at least two-thirds, particularly for lifetime evaluations.
Instead of subjecting numerous physical prototypes to stress tests, THOR’s digital twin can virtually simulate degradation and failure scenarios. This approach allows researchers to explore conditions that would be too costly or dangerous to recreate in the lab. THOR has already achieved a significant milestone by collaborating with Varta, an industrial partner, to produce prototype cells optimized for the model.
The project does not aim to eliminate physical testing but to improve its efficiency and focus. Daniel explains, “We want to test less, but learn more.” The innovation lies in integrating various testing dimensions—performance, lifespan, and safety—into a cohesive model. Current battery models often operate independently, making it challenging to predict how a battery will perform after years of use.
Wu envisions a digital twin as a real-time representation of a specific battery, incorporating factors such as aging, usage conditions, and sensor data. Advanced diagnostic tools, including ultrasound and X-ray tomography, can identify internal defects, while AI-driven models analyze vast datasets to foresee potential failures. This approach could drastically reduce the time and costs associated with determining whether a battery design is viable for scaling.
THOR’s methodology promises not only to hasten innovation but also to promote sustainability by minimizing material waste and improving validation efficiency. As over 90% of battery production currently occurs in Asia, Europe must leverage every possible advantage to remain competitive.
Monica Frassoni, President of the European Alliance to Save Energy (EU-ASE), highlights the economic benefits of energy-efficient processes. She asserts that reducing energy demand directly lowers production costs, which is critical for maintaining competitiveness in the global market. Despite some industries claiming they have maximized efficiency, Frassoni believes there remains substantial potential for improvement through electrification and process optimization.
The urgency for Europe to enhance its battery sector aligns with broader energy efficiency goals. A report from Transport & Environment urges the EU to streamline its battery strategy by providing clear investment signals and strengthening “Made in EU” provisions. Frassoni emphasizes that achieving energy efficiency targets is crucial for establishing credibility in future climate commitments.
While Europe has made strides in energy efficiency—reporting a 54% reduction against a 55% goal—efforts have lagged in other areas. Current progress shows only an 8% improvement in energy efficiency instead of the desired 11.7%. Frassoni warns that failure to meet the 2030 targets will complicate future climate goals.
The coming years will be pivotal as global demand for batteries is expected to quadruple by 2030. Therefore, those who can deliver rapid, safe, and sustainable battery solutions will likely lead the energy transition. With the THOR project and similar initiatives, Europe recognizes the urgency for swift action in battery technology development.
