Since 2022, Porsche and Porsche Werkzeugbau Group have collaborated to establish the Smart Battery Shop in Horná Streda, Slovakia, to produce battery modules entirely in-house for the next-generation Cayenne Electric. The 40,200-square-meter facility, adjacent to the existing Porsche Werkzeugbau Technology Center, was constructed between January and September 2023, with installation of production equipment starting in September and the first module completed in May 2024.
In a precisely controlled process, individual pouch cells undergo stringent ESD protection and cleanliness measures before testing and preparation. Cells are stacked with exact spacing and alignment, then inserted into carrier frames. Automated laser welding secures cell tabs, after which a foam material stabilizes the stacks. Four stacks are integrated into a module housing, thermal gaps are filled to enhance heat dissipation, cooling plates are bonded, and a top plate is welded to seal the module. End-of-line inspections include leak testing, electrical checks, dimensional and visual inspections, functional testing, and insulation measurements. Six modules form the high-voltage battery for the Cayenne Electric; an external contractor then assembles them into a complete battery pack and outfits it with high-voltage cabling and connectors for just-in-sequence delivery to the Bratislava assembly plant.
Real-time process data capture and cloud-based archiving provide full transparency and traceability throughout production. In-house laboratory validation subjects modules to performance and durability assessments under simulated conditions, including temperature cycling between 60 °C and 100 °C and immersion testing. This rapid development was enabled by close cooperation between technical development teams in Weissach and production planners in Zuffenhausen.
The Horná Streda site emphasizes environmental sustainability through on-site photovoltaic panels, heat pumps, greened roof areas, and its own well for water supply, helping to reduce CO₂ emissions and support local climate protection.
By integrating prototype expertise into series production and consolidating administrative functions, Porsche is strengthening its in-house battery know-how and quality control within Europe as part of its broader electromobility strategy.
Source: Porsche Newsroom
