The pace of battery innovation has long been stymied by complex R&D cycles and the reliance on expensive trial-and-error methods in physical laboratories. Today, however, Hexagon’s latest announcement may signal a new direction for battery technology, promising faster development cycles and potentially game-changing advancements for industries from automotive to consumer electronics.
In partnership with Fraunhofer ITWM, Hexagon has introduced a sophisticated electrochemical simulation solution. This virtual laboratory enables R&D departments to model new battery cell designs digitally, potentially saving vast resources and accelerating the path to market for next-generation batteries. Unlike traditional methods, this virtual solution uses digital twins to simulate the inner workings of a battery cell, allowing manufacturers to optimise performance and troubleshoot potential issues without extensive physical testing.
A digital approach to battery design
Battery research is notoriously slow and expensive. Bringing a new cell to market involves rigorous design-of-experiments (DoE) methods, often based on first principles and physical prototypes. Each design tweak requires its own lab test, which compounds costs and lengthens timelines. Hexagon and Fraunhofer ITWM’s new solution replaces much of this hands-on experimentation with precise digital models.
From Hexagon’s Digital Materials suite, users can simulate a cell’s entire internal structure, including the electrolyte, separator, active materials, binder, and current collector. By adjusting parameters such as particle size, shape, and surface area, R&D teams can explore how each variable affects energy efficiency, charging speed, and battery lifespan, essentially allowing them to test new configurations virtually. This level of digital design exploration enables faster iteration, meaning companies can more quickly arrive at an optimal battery design without the high costs of physical trials.
Performance optimization and safety
A particularly intriguing aspect of this technology is its potential impact on performance and safety—two core aspects for industries such as electric vehicles, where quality is paramount. For instance, manufacturers can analyse how battery aging affects efficiency or run simulations to establish optimal charging protocols that minimize wear. By offering insight into battery degradation over time, Hexagon’s solution could help engineers design safer, longer-lasting batteries that meet increasingly rigorous standards.
The solution also enables reverse engineering of cell structures from CT scans, opening new avenues for quality control. Using Hexagon’s VGSTUDIO MAX 3D metrology software, R&D teams can scan a physical cell and compare it to its digital twin, identifying any deviations caused by the manufacturing process. This ability to cross-check against a digital model offers manufacturers a powerful quality assurance tool, helping them identify defects early and ensure product consistency.
Integrating advanced modelling into R&D
Beyond the electrochemical model, Hexagon’s solution allows for detailed mechanical simulations. With its Digimat software, engineers can simulate not only the chemistry of a battery but also its physical behaviour under stress. This is particularly valuable in the automotive sector, where batteries must withstand significant mechanical loads. By evaluating the battery’s structural integrity, manufacturers can better anticipate and mitigate risks, designing cells that are both powerful and resilient.
Subham Sett, Vice President of Multiphysics at Hexagon, emphasises the strategic advantage this provides: “Battery performance and quality are competitive differentiators, particularly in the automotive market. Our solution gives manufacturers a holistic view of multiphysics interactions, allowing them to shift left in the design process, enabling more proactive decision-making.”
A step toward the future of sustainable energy
Battery technology has a critical role to play in the transition to sustainable energy. Advances like these from Hexagon and Fraunhofer ITWM not only shorten development cycles but may also lead to batteries that are more efficient, longer lasting, and environmentally friendly. By streamlining design processes and integrating quality assurance into R&D, Hexagon’s solution stands to accelerate innovation across sectors that increasingly rely on battery power.
Ultimately, this partnership between Hexagon and Fraunhofer ITWM reflects a larger trend toward digital transformation in industrial design. As the world moves toward electrification and the demand for high-performance batteries surges, solutions that eliminate bottlenecks and reduce costs will be essential. This virtual laboratory is not merely a step forward for battery R&D, it is a glimpse into the future of sustainable innovation.
