Designing EV Battery Cells for Long Range and Fast Charging
Modern EV buyers expect ~500 km of range and 20–30 minute fast charging as standard. Delivering both in a single battery platform means pushing energy density to its limits without sacrificing safety, thermal performance or lifetime.
In this on-demand webinar, Tomas (Product Manager, Embedded) and Dhammika (Head of Battery Modelling) from Breathe walk through how to:
Design high energy density cells using Breathe Design
How the Molicel P45B and Tesla 4680 cells behave when scaled across formats
Understand thermal and anode-potential trade-offs at high energy densities
Use adaptive charging to safely unlock fast-charge performance in real vehicles
Watch the webinar replay
What you’ll learn in this session
You will learn:
What EV buyers care about today - McKinsey data shows that 500 km range and 20–30 minute DC fast charging are now baseline expectations.
Why “range added in 10 minutes” is becoming the dominant fast-charge KPI
This metric reflects real driving experience and is much harder to manipulate than 10–80% charge times.How to design high energy density cells
Using simulation to understand the impact of NP ratio, cathode loading, electrode porosities, thicknesses, and recipe changes.How the Molicel P45B and Tesla 4680 cells behave when scaled
What increases (capacity, volumetric energy) and what risks grow (thermal gradients, heat flux, resistance).The thermal and safety trade-offs that emerge at higher energy densities
Including detailed behaviour of anode potentials under fast charging.How software and real-time estimation expand what hardware can safely deliver
And why adaptive charging can safely reach performance that lookup tables cannot.
Who this webinar is for
Cell design and electrochemistry teams
Battery pack and thermal engineers
EV platform and product owners
Modelling, simulation, and validation engineers
See Breathe Design in action
The webinar includes a comparison of Molicel P45B and Tesla-derived 4680 parameters, showing how each cell behaves when evaluated in 4680-scale designs using Breathe Design.
In the demonstration, you’ll see how Breathe Design helps you:
Start from a parameterised commercial cell such as the Molicel P45B
Inspect static KPIs including capacity, nominal voltage, mass, and volumetric energy density
Explore design sensitivities such as NP ratio, cathode loading, voltage limits, porosity and thickness
Compare redesigns (for example 5% NP ratio reduction or 5% cathode loading increase)
Run dynamic simulations including 3C charging, temperature rise, and anode potential behaviour
Want to go deeper with your own cells?
If you want to evaluate your own cells using this workflow, Breathe offers:
Cell parameterisation
You send 10 cells. Breathe performs teardown, characterisation, parameterisation and validation.
Your cell models then become available inside Breathe Design and Breathe Model.Co-design studies
Work with Breathe to explore NP ratio, cathode loading, format variations, thermal constraints, and fast-charge strategies.