RWTH Aachen University’s Chair of Production Engineering of E-Mobility Components (PEM) is spearheading a new European research initiative called RESiLiTE, which aims to develop safer and more efficient battery packs for electric vehicles. The project, supported by approximately €6.2 million in EU funding, brings together academic and industry partners from Germany, Austria, Spain, Portugal, Slovenia and Turkey. If successful, the developed technologies will also be adapted for use in the aviation sector.
At the heart of the RESiLiTE concept are cylindrical cells housed within thermoplastic enclosures. By integrating the cell holders directly into these housings, the design eliminates the need for conventional casting materials. This structural innovation is expected to deliver an energy density of around 220 watt-hours per kilogram at the pack level—more than 14 percent above current benchmarks—and enable charge and discharge rates exceeding 4.5C through combined indirect cooling embedded in the housing.
Safety and performance under varied conditions are key focuses of the project. Researchers will employ advanced diagnostic software to assess cell health using electrochemical impedance spectroscopy. Thermal management will be enhanced through scenario-based neural network algorithms, which dynamically regulate temperature to improve energy efficiency. The use of thermoplastic materials offers inherent insulation, extending operating times in cold environments and delaying the need for active heating systems.
Beyond technical improvements, RESiLiTE partners anticipate that the proposed measures and materials will lower total cost of ownership over the life of the battery packs by boosting durability and system robustness. Enhanced thermal insulation, precise state-of-health monitoring and higher energy density are expected to contribute to longer service life and greater operational resilience compared to current state-of-the-art solutions.
Source: PEM RWTH Aachen University
