Cornell engineers have come up with a solution to a tricky problem: where to install charging stations for electric vehicles so they’re convenient for drivers and profitable for investors.Without abundant and well-placed charging stations, consumers will purchase fewer electric vehicles. Without enough electric vehicle owners, publicly available charging stations won’t be profitable; that means there will be fewer of them.“Improving charging-station infrastructure is essentially the chicken-and-the-egg problem,” said co-author&nbsp;<a href="https://www.cee.cornell.edu/faculty-directory/h-oliver-gao">Oliver Gao</a>, the Howard Simpson 1942 Professor of Civil and Environmental Engineering at Cornell Engineering.The research team found that in urban settings, installing an equal mix of two different kinds of stations – one that charges at a medium speed and another that charges more quickly – and distributing them strategically increases the chances that drivers will use them. And that in turn improves the profitability for investors by 50% to 100%, compared to current random placement strategies.The research, “<a href="https://www.sciencedirect.com/science/article/pii/S0306261924013588">Bayesian Optimization for Battery Electric Vehicle Charging Station Placement by Agent-Based Demand Simulation</a>,” published Aug. 9 in Applied Energy.“Placing publicly available charging stations around cities sounds like a simple thing, but mathematically, it’s actually very hard,” said lead author Yeuchen Sophia Liu, Ph.D. ’22, an operations researcher in Gao’s laboratory.That’s because simple models don’t allow for the complexity of thousands of possible driver decisions, Liu said, not to mention factors like traffic and road characteristics.So the team reached back six decades to use Bayesian optimization, a mathematics strategy that uses past attempts at optimization to inform each subsequent attempt. That results in a much faster and productive analysis. It has become popular in machine learning algorithms.“The Bayesian optimization model algorithm allows us to simulate millions of individual behaviors, while at the same time, find answers efficiently and quickly,” Liu said.The team set up an algorithm that used Bayesian optimization to analyze data from the Atlanta region, home to about 6 million people. They studied the behavior of 30,000 vehicles on more than 113,000 simulated trips, forecasting a variety of commuter traffic patterns.The algorithm found an optimal placement using only 2% of the runtime of existing benchmark methods. “This enables the use of the algorithm on a more complex, real-world scale,” Liu said.The team found that medium speed “level-2” commercial charging stations and direct-current, fast-charging “DCFC” stations serve different needs. Drivers who park for 20 minutes – while running into a grocery store, for example – are likely to choose fast charging spots. But if someone is going to work and parking for several hours, the driver will likely select the level-2 station.In addition, a sensitivity analysis demonstrated that factors such as the size of the battery electric vehicle market, charging preferences and charging price have significant impacts on the optimal placement and profitability of an electric vehicle charging infrastructure project.The findings have important implications, Liu said. In the U.S., according to the paper, eight states have adopted California’s Zero Emission Vehicle program mandate to have at least 3.3 million zero-emission light-duty vehicles – replacing carbon combustion engine cars – on the road by 2025.“Economically strategic placement of charging stations could play a pivotal role in accelerating the transition to zero-emission vehicles,” Liu said.In addition to Liu and Gao, co-authors are Mohammad Tayarani, a visiting scientist in Gao’s lab, and&nbsp;<a href="https://www.cheme.cornell.edu/faculty-directory/fengqi-you">Fengqi You</a>, the Roxanne E. and Michael J. Zak Professor in Energy Systems Engineering in Cornell Engineering. The work was funded by a grant from the U.S. Department of Transportation.&nbsp;

Cornell engineers have come up with a solution to a tricky problem: where to install charging stations for electric vehicles so they’re convenient for drivers and profitable for investors.

Placement strategy key to getting most out of EV charging stations

For fourth-year student Jonathan Smith, coming to Penn State was a no-brainer. His parents attended Penn State Harrisburg, and he lived in the Berks County area, so he knew early on where he wanted to continue his education.As for his major, though, the path he followed took him by surprise, he said. In his first year at Penn State Berks, he took an engineering class that would shift his priorities — and launch a startup that has given him clear goals for a future in architectural engineering.&nbsp;“At the end of the semester, there was a competition for sustainable energy charging. So my team pitched an idea to put solar panels on the side of a building, and it powered an electric-vehicle charging station,” Smith said. “We didn’t win that competition, but the four of us continued working on the idea as an independent study.”&nbsp;The team went back to the drawing board and focused on research. They started talking to electric vehicle customers through a program focused on customer discovery, Smith said, and the input they collected helped them to rework their ideas for charging ports.&nbsp;“We did a satisfaction survey, and everyone who could charge at home was extremely satisfied,” Smith said. “But in apartment buildings, 60% of people were satisfied, because they're always butting heads with their neighbor for charging stations or they had to charge on their way to work. It’s just a complete headache.”&nbsp;<aside data-testid="quote-inline"><blockquote>“We hope we give people, the business owners and the apartment complex owners, something that’s feasible to install. They see the financial payback, and people can charge the car quickly at home.”- Jonathan Smith,&nbsp;Penn State student, Streamline Charging CEO</blockquote></aside>Current charging stations can cost as much as $8,000 to install, according to Smith, but they have a limited reach. Codes and regulations restrict their charging cables to 25 feet in length, which means they can only service one or two parking spaces each. In buildings like apartment complexes, that limits the number of people and spaces that can use the stations.&nbsp;Smith and his team used their research to create a possible solution: smaller, mounted charging stations, which can slide on a mount to cover as many as five parking spaces. The installation process could be cheaper, he said, and less disruptive for the property.&nbsp;“We hope we give people, the business owners and the apartment complex owners, something that’s feasible to install,” Smith said. “They see the financial payback, and people can charge the car quickly at home. I think would be really cool.”&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1729896046692-24-10-3-originlab-jon-portrait.jpg" style="width: 100%px;" class="fr-fic fr-dib">Jonathan Smith and his team at Streamline Charging LLC are working to create an electric vehicle charger that provides more flexibility on a smaller budget with support from Penn State. Credit: Patrick Mansell / Penn State.As they’ve reworked the proposal, Smith and his team have found significantly more success. During the spring 2024 semester, they won $5,000 from a competition that will go toward building the first prototype model. The team has grown from the original four-person crew to anywhere from 10-15 people depending on the semester and what they need to accomplish.&nbsp;Their startup, Streamline Charging, also has won about $45,000 in funding from national grants, Smith said. The LLC was <a href="https://www.psu.edu/news/invent-penn-state/story/six-student-startups-compete-30000-incu-competition/" rel="noreferrer noopener" target="_blank">a finalist in the 2024 Inc.U Competition</a> from Invent Penn State, <a href="https://www.psu.edu/news/berks/story/student-team-developing-ev-charging-stations-receives-awards-and-recognition/" rel="noreferrer noopener" target="_blank">winning $10,000</a>. It also <a href="https://www.psu.edu/news/berks/story/penn-state-berks-students-receive-student-enterprise-award-funding/" rel="noreferrer noopener" target="_blank">received additional financial support</a> from the Flemming Creativity, Entrepreneurship, and Economic Development (CEED) Center earlier this year through the Student Enterprise Awards, and were part of the <a href="https://www.psu.edu/news/berks/story/penn-state-berks-student-startup-received-venturewell-e-team-program-grant/" rel="noreferrer noopener" target="_blank">2023 summer cohort of VentureWell Accelerator E-Team program</a>.&nbsp;Smith serves as CEO for the company, and the experience has opened up options for his future as he starts looking beyond graduation. The financial opportunities through Invent Penn State, alongside <a href="https://www.psu.edu/news/berks/story/berks-student-team-developing-ev-charging-stations-receives-national-recognition/" rel="noreferrer noopener" target="_blank">Happy Valley LaunchBox programs like the Fast Track Accelerator</a>, have been instrumental in the company’s success, he said.&nbsp;“We’ve had so many professors and people to help us and coach us along the way,” Smith said. “I knew we wanted to make this a business, but we had no idea how to do that. Without LaunchBox, without support from Penn State Berks, we never would have been able to get as far as we have. It’s really exciting that Penn State was able to foster that.”&nbsp;Smith said a prototype is set up at Penn State Berks, and the company is working to install the first fully market-ready version in State College to show appreciation for the support they’ve gotten at the University.&nbsp;That support also includes guidance from Berks professor Kathy Hauser, who ran the first engineering course where Smith first started to develop this idea. Hauser has continued to mentor the team through independent study courses, helping them to implement their ideas.&nbsp;The project was a learning experience for the students, Hauser said, showing them how to navigate real-world business needs and hurdles. But it’s also been a chance for her to learn and try new strategies for her classes.&nbsp;“This project started out almost as an experiment,” Hauser said. “It was this weird kind of thing because it wasn't undergraduate research. It was a chance to expand upon a project with first-year students who really don't have engineering backgrounds.”&nbsp;Typically, Hauser works with third- and fourth-year students to form teams for competitions and business concepts. Because these students are in the midst of wrapping up their academic degrees, they don’t have as many opportunities to hone their idea and pitch.&nbsp;“So we wondered if it was possible to put a team of freshman together and let them explore their own projects, then enter competitions as juniors with a developed idea,” Hauser said.&nbsp;Hauser used her entry-level engineering course, EDSGN 100, as a chance to find teams of first-year students and figure out those ideas. During Smith’s time in the class, there was a specific task to address. A sponsor wanted teams to develop a charging station specifically for Penn State Berks.&nbsp;<aside data-testid="quote-inline"><blockquote>“The reality of it is, if you come up with something, Penn State will help you do it right. Penn State can be very supportive.”- Kathy Hauser,&nbsp;professor, Penn State Berks</blockquote></aside>But Hauser said Smith and his team ended up pursuing their own ideas outside those parameters. They looked at the automotive industry and data connected to the rollout of electric vehicles to determine what was working and what wasn’t, with a broader focus than just designing something that would work at their campus. Hauser gave them the space to pursue that, instead.&nbsp;“That was what we then shifted to, very early in the semester,” Hauser said. “I said, ‘The reality of it is, if you come up with something, Penn State will help you do it right. Penn State can be very supportive.’”&nbsp;Hauser has continued to guide Smith and his team through five semesters of developing and refining an idea that excites them — the movable charging station they’re now working to assemble. The team has changed over time as students dropped out or joined up with the project, Hauser said, but the project hasn’t lost steam.&nbsp;“I teach freshmen, predominantly, and I generally only see them that first year. The only ones I really get to know are my advisees,” Hauser said. “It's been entirely different to continue with these students over three years and really get to know them on a much more personal basis. That's been really fun.”&nbsp;The goal, she said, has always been to give Smith and his team the kind of valuable experience that would serve them well in the future. But the success of the Streamline Charging project has been incredible, she said.&nbsp;“If you want to get an internship by your second year, this was a good class to take. That's all I wanted. Anything else that comes out of it is just kind of the icing on the cake,” Hauser said. “But this team has had a lot of icing on their cake.”&nbsp;Hauser has had other cohorts and teams that came together after Smith’s group, but they haven’t been able to propel a project to the same heights — whether because it didn’t align with their majors or because they didn’t have enough time to commit to it. A new group now has potential, and she’s hoping that Smith’s team has created a path that other teams can start to follow to success.&nbsp;“When you see them latch onto what you taught them or get excited about what you're passionate about, you're really proud of those moments,” Hauser said. “This is why I like teaching. It's knowing that you can make a difference and that those things will have a lasting impact.”&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1729896089008-24-10-3-originlab_jon-0001.jpg" style="width: 100%px;" class="fr-fic fr-dib">Lead Product Engineer Marcelo DeLeon, left, in OriginLabs with Jonathan Smith. The two are working together as Smith's company, Streamline Charging, prepares to install its first electric vehicle charger in State College.&nbsp;Credit: Patrick Mansell / Penn State.Through Hauser’s guidance, Smith said, he’s been able to build his idea into something that might become a long-term plan for himself. He’s also had the chance to connect with other Penn Staters willing to help him along the way.&nbsp;“In architectural engineering, we have a huge alumni network. That's where I met a lot of the people who have talked with us about growing this into something more,” Smith said. “We have so many people that really want to see us succeed.”&nbsp;Penn State also has assisted with patents and licensing, Smith said, offering students a chance for real benefit from the work they do.&nbsp;“Right now, I'm trying to talk to manufacturers to build the final station. We can look to raise more money soon and, when I graduate, I might be able to work on this full time,” Smith said. “Honestly, it's so much fun. I have an opportunity to decide for myself what to do with my career and my ideas.”&nbsp;

Streamline Charging is preparing to install its charging station in State College. CEO and Penn State student Jonathan Smith works on the parts for the chargers in OriginLabs on Burrowes Street, where he can benefit from support from Penn State. Credit: Patrick Mansell / Penn State.

Penn State student Jonathan Smith works with team to create potential solutions for accessible EV charging

Building a flexible and affordable electric-vehicle charging station

<h2 dir="ltr" id="isPasted">Introduction</h2>In modern automotive engineering, Metal Oxide Semiconductor Field Effect Transistors (MOSFETs) are fundamental components that enhance the performance, efficiency, and safety of vehicle electronics. Serving as key components in power management systems, motor controls, safety mechanisms, and various other vehicle subsystems, the reliability and performance of MOSFETs significantly impact the efficiency, safety, and overall driving experience of both electric vehicles (EVs) and internal combustion engine (ICE) vehicles. Consequently, the quality of MOSFETs is a non-negotiable aspect.This article provides a detailed look at high-performance MOSFETs tailored for automotive applications, focusing on their essential functions, performance metrics, and rigorous quality standards. Additionally, it examines Nexperia's contributions to the evolution of the technology, highlighting real-world applications and discussing the trends currently shaping the industry.<h2 dir="ltr">Understanding Automotive MOSFETs</h2>MOSFETs are pivotal components in the architecture of modern automotive electronics. Their ability to efficiently switch and amplify power makes them a critical component across various systems within vehicles.<h3 dir="ltr">Function and Importance of MOSFETs in Automotive Systems</h3>MOSFETs are integral to the functionality of numerous automotive systems, serving as critical components in power management and signal processing across various applications. Their ability to handle high currents and voltages efficiently while switching and amplifying signals makes them a vital electronic component in modern vehicles. Here’s a closer look at some specific applications:<ul><li dir="ltr" style="font-weight: bold;">Powertrain and Vehicle Dynamics:<ul style="font-weight: initial;"><li dir="ltr">Advanced Driver Assistance Systems (ADAS) radar sensor module:&nbsp;MOSFETs regulate the power distribution to the radar components of ADAS, ensuring optimal performance by managing the precise control of high currents needed for the radar's operation.</li><li dir="ltr">Electronic Power Steering (EPS): MOSFETs modulate the power supplied to the electric motor that drives the steering mechanism, allowing for precise control and responsiveness, enhancing both the efficiency of steering operations and the overall safety and comfort for the driver.</li><li dir="ltr">Anti-locking braking systems/Electronic Stability Control (ABS/ESC): Critical in providing the rapid switching needed for effective electronic stability control and braking systems.</li></ul></li><li dir="ltr" style="font-weight: bold;">Vehicle Comfort and Convenience:<ul style="font-weight: initial;"><li dir="ltr">Adaptive Front LED lights and Interior LED lighting:&nbsp;MOSFETs drive the lighting systems, offering precision control that adapts to varying conditions and user settings.</li><li dir="ltr">Automatic Heating Ventilation and Air Conditioning (HVAC):&nbsp;Ensures efficient motor control for heating, ventilation, and air conditioning, enhancing passenger comfort.</li><li dir="ltr">Active Suspension System: MOSFETs facilitate the rapid adjustment of suspension settings to adapt to road conditions to improve ride quality and vehicle handling. This technology contributes to a smoother driving experience by dynamically managing the suspension's response to changes in terrain.</li></ul></li><li dir="ltr" style="font-weight: bold;">Safety Systems:<ul style="font-weight: initial;"><li dir="ltr">Airbag controller with Safing MOSFET:&nbsp;Controls the deployment of airbags in a crash situation, ensuring timely and reliable activation.</li><li dir="ltr">Seat Belt Pretensioners and Force Limiters: MOSFETs control the mechanisms that tighten seat belts instantly during a collision, reducing slack to protect occupants. They also regulate the force limiters to ensure that the belt tightens adequately without causing injury, enhancing passenger safety during severe impacts.</li></ul></li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1729694339156-image1.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="mosfet-applications-vehicle"><ul id="isPasted"><li dir="ltr" style="font-weight: bold;">Power Management in EVs/Hybrids:<ul style="font-weight: initial;"><li dir="ltr">High power, high-efficiency DC/DC converter and On-Board Charger (OBC): Essential for converting and managing power within the vehicle’s electrical system, crucial for electric and hybrid vehicles.</li><li dir="ltr">Zonal Control Units: MOSFETs facilitate intelligent power distribution controlled by software, optimizing the delivery of power to different zones of the vehicle. This not only enhances the efficiency of electrical systems but also supports advanced features such as customized lighting and climate control across different cabin areas.</li><li dir="ltr">Battery Management System (BMS):&nbsp;MOSFETs play a crucial role in managing systems that monitor and control battery packs, crucial for EV performance and safety. They also help in the balanced charging of battery cells, a process that is critical for maintaining the health and extending the lifetime of the battery. By ensuring each cell within the battery pack is charged correctly, MOSFETs prevent overcharging and help maintain the overall battery balance, thus safeguarding and maximizing battery life.</li></ul></li><li dir="ltr" style="font-weight: bold;">Applications in ICE vehicles:<ul style="font-weight: initial;"><li dir="ltr">Cooling Fan and Fluid Pump Controls:&nbsp;Manage the operation of cooling systems and fluid circulation, which are vital for maintaining the operational integrity of engine and battery systems.</li><li dir="ltr">Electronic Fuel Injection:&nbsp;Improves the efficiency and control of fuel delivery to the engine, optimizing performance and reducing emissions.</li></ul></li></ul>MOSFETs’ versatility enables them to support these (and many more) critical functions across various systems within the vehicle, highlighting their importance in the automotive industry.<h3 dir="ltr">Key Performance Metrics for MOSFETs</h3>The high performance, efficiency, and reliability of MOSFETs in automotive applications are essential for ensuring the smooth operation of vehicle electronics. These metrics include:<ul><li dir="ltr" style="font-weight: bold;">Electrical Efficiency:<ul style="font-weight: initial;"><li dir="ltr">Switching Efficiency:&nbsp;Effective switching speeds for automotive power MOSFETs typically range from tens to hundreds of nanoseconds, essential for fast response times in power-intensive applications. Small signal MOSFETs, which are also qualified for automotive use, can switch in just a few nanoseconds, providing even faster response for applications requiring high-speed signal processing.</li><li dir="ltr">On-state Resistance:&nbsp;Lower on-state resistance increases efficiency by reducing power losses. Typical values range from 10 mΩ to sub &lt;1mΩ, ideal for minimizing heat generation and energy wastage.</li><li dir="ltr">Power Limits:&nbsp;These are determined by the maximum voltage and current the MOSFET can handle—commonly between 5V to 100V and 10A to 2000A—suitable for a variety of automotive functions.</li></ul></li><li dir="ltr" style="font-weight: bold;">Thermal Performance:<ul style="font-weight: initial;"><li dir="ltr">Operating Temperature Range:&nbsp;Automotive MOSFETs must operate effectively within a range of -55°C to +150°C, with short-term tolerance of up to 175°C for high-heat environments such as engine compartments.</li><li dir="ltr">Thermal Resistance of Junction-Base Mounting: &nbsp;This parameter, ranging from 0.5K/W to 2K/W, indicates the capability of heat dissipation. Lower values are preferable, as they denote superior thermal management.</li></ul></li><li dir="ltr" style="font-weight: bold;">Durability and Longevity:<ul style="font-weight: initial;"><li dir="ltr">Thermal Cycling Resistance:&nbsp;MOSFETs are designed to withstand numerous thermal cycles without performance degradation, ensuring long-term reliability. Additionally, they must pass rigorous electrical bias stress tests, including high temperature gate bias, high temperature reverse bias, and humidity bias stress. These tests are critical for assessing the durability of MOSFETs under severe environmental conditions and electrical stresses, further ensuring their robustness and suitability for demanding automotive applications.</li></ul></li></ul>Suggested reading:&nbsp;<a href="https://www.wevolver.com/article/next-generation-mosfet-technology-meets-demand-for-strong-thermal-performance-in-automotive-applications" target="_blank">Next-generation MOSFET technology Meets Demand for Strong Thermal&nbsp;Performance in Automotive Applications.</a><h2 dir="ltr">Quality Standards and Certifications</h2>MOSFETs used in automotive applications are subject to specific industry standards that dictate their design, testing, and performance criteria. One of the most critical standards is the AEC-Q101, a stringent specification from the Automotive Electronics Council that covers stress tests for semiconductors in automotive applications. This standard ensures that MOSFETs can withstand extreme conditions such as high temperatures, vibrations, and varying electrical loads.Compliance with AEC-Q101 involves multiple tests, including thermal shock, moisture resistance, electrostatic discharge susceptibility, and life-cycle testing. These tests are designed to simulate the actual operating conditions that MOSFETs will face in a vehicle, ensuring that only the most robust components make it into automotive systems.&nbsp;Suggested reading: <a href="https://www.wevolver.com/article/semiconductor-resilience-with-innovations-in-testing-techniques-and-packaging" target="_blank">Semiconductor Resilience with Innovations in Testing Techniques and Packaging</a><h2 dir="ltr">Trends and Innovations</h2>The automotive industry is on the brink of a big technological transformation, with MOSFETs playing a crucial role in shaping the future of mobility. As the demand for EVs and autonomous driving systems increases, MOSFETs are evolving to meet the new challenges and performance requirements.New materials such as Silicon Carbide (SiC) and Gallium Nitride (GaN) are making their way into MOSFET design. These materials offer superior efficiency, higher breakdown voltage, higher temperature tolerance, and faster switching capabilities than traditional silicon MOSFETs, making them ideal for the high-power demands of EV powertrains and charging systems.Additionally, the integration of intelligent control features within vehicle subsystems is becoming more common. Smart power converters can provide real-time diagnostics and protection features, enhancing the overall safety, reliability and repairability of automotive electronics.Moreover, as vehicles become more connected and autonomous, the number of electronic components and systems is set to increase continuously, necessitating MOSFETs that can perform reliably in a more crowded and interconnected environment. The ongoing development in MOSFET technology also aims to reduce interference and improve communication between components, ensuring seamless operation.<h2 dir="ltr">Nexperia's High-Performance MOSFETs: Driving Excellence and Innovation in Automotive Electronics</h2>Nexperia distinguishes itself in the automotive electronics market with a strong focus on quality, performance, and innovation. As a semiconductor manufacturer, Nexperia is committed to developing MOSFET technology that meets the stringent requirements of modern automotive systems.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1729694884790-image3.png" style="width: 100%px;" class="fr-fic fr-dib" alt="lfpak-family">MOSFETs optimized for Automotive applications by Nexperia in an LFPAK package. Source: Nexperia<h3 dir="ltr">Innovative Product Range</h3>Nexperia’s automotive MOSFET product portfolio contains over 400 types of power MOSFETs, with specifications ranging from -18 &nbsp;to 500 A for drain currents and drain-source voltage ratings ranging from -60to 100 V. These are housed in robust copper-clip packages featuring cutting-edge technologies, such as flexible leads and wettable flanks for ease of Automatic Optical Inspection (AOI) and improved reliability. This diversity ensures solutions for every automotive electronic need, from simple lamp circuits to complex power requirements of vehicle electrification and hybrid battery systems.Suggested reading:&nbsp;<a href="https://www.wevolver.com/article/a-story-of-innovation-how-lfpak-revolutionized-an-industry" target="_blank">A story of innovation: How LFPAK revolutionized an industry.</a><h3 dir="ltr">Focused on Future Needs and Sustainability</h3>Nexperia is further advancing MOSFET technology with initiatives like the introduction of the <a href="https://www.nexperia.com/products/sic-mosfets" target="_blank">1200 V Silicon Carbide MOSFETs</a>, which enhance efficiency and reduce energy waste—crucial for extending the driving range of EVs. The company's efforts in scaling down MOSFET sizes allow for more compact system designs without compromising performance or reliability. These innovations support the automotive industry’s goals of reducing carbon footprints and advancing sustainable mobility solutions.<iframe width="640" height="360" src="https://www.youtube.com/embed/pD7b3YkhG6s?&amp;pp=ygUPbmV4cGVyaWEgbW9zZmV0&amp;wmode=opaque&amp;rel=0" frameborder="0" allowfullscreen="" class="fr-draggable">&nbsp;</iframe><h3 dir="ltr">Specialization for Reliability</h3>Tailoring MOSFET offerings to specific automotive needs ensures that each component delivers optimal performance and efficiency. Nexperia’s MOSFETs are essential in systems ranging from adaptive lighting and climate control to critical applications like electric power steering and braking systems. Innovations in packaging and silicon technologies enhance thermal performance and durability, vital attributes where reliability and space economy are most important.Nexperia upholds a zero-defect culture, which has been recognized through multiple supplier awards, reflecting their commitment to excellence. Impressively, the company has maintained a complaint rate of less than 0.05 complaints per million since 2019, emphasizing their relentless focus on quality.&nbsp;In addition to these innovations, Nexperia provides next-generation support tools for automotive engineers. Their interactive datasheets allow real-time adjustment of parameters like voltage, current, and temperature, instantly visualizing MOSFET behavior. This streamlines design workflows by eliminating manual calculations and circuit simulations. Advanced electrothermal MOSFET models also enable early-stage validation of circuit designs, helping identify EMI and EMC issues upfront.Nexperia's ongoing innovations and focus on quality support automotive manufacturers in developing more efficient, reliable, and cost-effective electronic systems. These advancements contribute to vehicles that offer improved safety, comfort, and environmental performance.Visit <a href="https://nexperia.com/mosfets" target="_blank">Nexperia's official website</a> to explore a range of advanced MOSFET solutions built for automotive electronics.<h2 dir="ltr">Conclusion</h2>Nexperia's ongoing commitment to innovation in MOSFET technology highlights the critical role these components play in improving vehicle performance, efficiency, and safety. By leveraging advanced materials and innovative designs, Nexperia ensures that automotive electronics meet stringent contemporary standards and are equipped for the evolving demands of tomorrow. As the shift towards more electric and autonomous vehicles continues, the need for reliable, efficient, and high-performance MOSFETs becomes increasingly apparent.<h2 dir="ltr">References</h2>[1] Nexperia. Driving solenoids in automotive applications Rev. 1.1 [Internet]. 3 Nov 2023. Available from:<a href="https://assets.nexperia.com/documents/application-note/AN50003.pdf" target="_blank">&nbsp;https://assets.nexperia.com/documents/application-note/AN50003.pdf</a>[2] Nexperia. MOSFET and GaN FET Application Handbook [Internet]. 19 Nov 2020. Available from:<a href="https://efficiencywins.nexperia.com/efficient-products/mosfet-and-gan-fet-application-handbook" target="_blank">&nbsp;https://efficiencywins.nexperia.com/efficient-products/mosfet-and-gan-fet-application-handbook</a>[3] Nexperia. Selection Guide: Discrete, MOSFET and GaN FET components, analog &amp; logic ICs [Internet], Available from: <a href="https://assets.nexperia.com/documents/selection-guide/Nexperia_Selection_guide_2023.pdf" target="_blank">https://assets.nexperia.com/documents/selection-guide/Nexperia_Selection_guide_2023.pdf</a>

Nexperia's automotive MOSFETs enhance innovation across both traditional and electric vehicles, expertly managing a wide array of applications from simple lighting to advanced electrification systems, ensuring high performance, reliability and superior efficiency in every aspect.

High-Performance MOSFETs Driving Excellence and Innovations in Automotive Electronics

In this episode, we explore a groundbreaking smart charger that could significantly boost the adoption of electric vehicles (EVs) by revolutionizing charging infrastructure, making EVs more accessible and sustainable for the future of transportation.

Podcast: This Smart Charger, More EVs

This article was discussed in our <a href="https://www.wevolver.com/profile/the.next.byte" rel="noopener noreferrer">Next Byte podcast</a>.&nbsp;<iframe height="200px" width="100%" frameborder="no" scrolling="no" seamless="" src="https://player.simplecast.com/0c6e89ec-2577-48b1-81ca-2b54787cba8e?dark=false" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe> The full article will continue below.<hr>In 2024, more than one in five cars sold is an electric vehicle (EV). Intergovernmental agencies estimate that by 2035, <a href="https://www.iea.org/reports/global-ev-outlook-2024/outlook-for-electric-mobility" target="_blank" data-entity-type="node" data-entity-uuid="df17f5fe-cbc3-4e3c-86ce-928e3a540089" data-entity-substitution="canonical">half of all new cars sold globally will be EVs</a>.&nbsp;While more EVs on the road sounds like great news for the environment, it could lead to complications. The electric grid is not yet ready to support the EV influx, and unaddressed capacity limitations could threaten the future of the EV industry.&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI5MDM4NTYxNjgxLWV2LWZlYXR1cmUtMS5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib">David Taylor, professor in the School of Electrical and Computer Engineering (ECE); Kartik Sastry, a recent ECE Ph.D. graduate; and Michael Leamy, Woodruff Professor and director of Graduate Studies in the School of Mechanical Engineering.Researchers at the Georgia Institute of Technology have developed a device to help avoid grid overload: a revolutionary EV smart-charging system.&nbsp;Their optimization-based approach would not only help reduce grid stress but also enable users to customize the charging process and minimize cost, prioritize the use of carbon-free energy, or adjust the charging speed. The technology might even help promote the EV industry.&nbsp;“The EV revolution is happening so quickly that electrical utilities will find it difficult and costly to update the grid fast enough to accommodate these vehicles,” said <a href="https://research.gatech.edu/node/36005" data-entity-type="node" data-entity-uuid="df17f5fe-cbc3-4e3c-86ce-928e3a540089" data-entity-substitution="canonical">Michael J. Leamy</a>, Woodruff Professor and director of Graduate Studies in the <a href="https://www.me.gatech.edu/">George W. Woodruff School of Mechanical Engineering</a>. “We wanted to investigate a way of smart charging that considers EVs as they converge on the electric grid, which we already know is near its maximum capacity. We need to buy time for the grid operators so they aren’t overwhelmed when more EVs enter the market.”<h2 id="isPasted">Taking a Load Off (the Grid)</h2>In the southeastern U.S., during the summertime, power use peaks from late afternoon to early evening. By then, the heat of the sun has warmed up homes and buildings, and people have cranked up their air conditioners. This is also when most people come home from work and plug in their EVs, which immediately start charging. When plugged in, an EV can easily be the most significant consumer of power in a home.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI5MDM4NTk2OTQ5LWV2LWZlYXR1cmUtMy5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib">The smart charger minimizes stress on the electric grid by using algorithms to distribute charging over time.“A bunch of EVs charging during the peak power load can be problematic for utilities, exacerbating electricity demand and overloading the grid,” said <a href="https://kartik.ece.gatech.edu/">Kartik Sastry</a>, a recent Ph.D. graduate in the <a href="https://ece.gatech.edu/">School of Electrical and Computer Engineering (ECE)</a> and co-inventor of the technology. “But you don’t need to start charging as soon as you come home. In most cases, there’s ample time overnight to fully charge electric vehicles.”&nbsp;The team set out to address the issue of grid overload by taking advantage of overnight surplus charging time. They developed cutting-edge optimization algorithms to distribute charging over time, thereby minimizing grid stresses while offering benefits to consumers.&nbsp;Rather than charging at full speed as soon as an EV is plugged in, the team’s smart-charging algorithms allow for gradual charging, or charging at several intervals over time rather than all at once. The algorithms also decrease the maximum power draw of a home during charging, achieving what the researchers call “peak shaving.”&nbsp;The algorithm itself plans the charging and when it will occur, based on the state of the grid and consumer preferences. The system also makes these decisions without the need for any centralized control, and without communicating with other vehicles in the neighborhood or city.&nbsp;“By using random timing and predictions of household power usage, our algorithm can effectively distribute the load,” said <a href="https://research.gatech.edu/node/36240" data-entity-type="node" data-entity-uuid="8797f559-5d41-4aea-afa6-46ef49f0b6e2" data-entity-substitution="canonical">David G. Taylor</a>, ECE professor and co-inventor of the charging system. “This means that the number of EVs in a community can increase without the local utility incurring huge expenses for infrastructure upgrades, provided these EVs use the smart charging algorithm we've developed.”<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI5MDM4NjUzNzM1LWltYWdlcyAoMSkuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">Customizable Charging</h2>The system allows consumers to customize their charging. Using an app the team designed, a consumer can control four different facets of charging: cost, carbon-free energy, speed, and battery health. The app’s slider widgets allow a user to weigh their preferences for each; based on the user’s selections, the algorithm determines how best to charge the vehicle while minimizing grid impact.&nbsp;For example, to charge their vehicle quickly, a user would move the charging-speed slider all the way to the right. Prioritizing carbon-free charging, on the other hand, programs the charger to only charge the car when renewable resources such as wind or solar are available on the grid. Choosing to charge at the lowest cost would prompt the system to charge at low-demand times based on a utility’s price schedule, allowing the user to avoid any demand charges.<h2 id="isPasted">Driving Forward</h2><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI5MDM4NjgwOTY5LWV2LWZlYXR1cmUtMi5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib">The team plans to demonstrate how their smart-charging algorithms can reduce costs for entire fleets of electric vehicles.The team has published several research articles about the project in major journals. They have also built prototype hardware, completed charging case studies with individual EVs, and submitted a patent for the technology.&nbsp;Expanding beyond the system’s applications for individual consumers, the team has also developed this technology to function in commercial settings. They hope to collaborate with an EV charging station company and a public school system that uses EV buses to demonstrate how their algorithms automatically reduce fleet charging costs.&nbsp;The goal, Leamy says, is for companies to license their smart-charging algorithm technology.The researchers are also reaching out to auto companies to have their technology incorporated into EVs themselves, which would allow users to set their charging preferences right from their dashboard.&nbsp;“We hope to demonstrate that smart charging is feasible on a large scale — and also measure the benefits of doing so,” Leamy said. “We plan to show how much money consumers, companies, and school systems can save with smart charging rather than simply charging in an ad hoc fashion.”“We anticipate a significant uptick in EV adoption, which will lead to higher demand on the grid,” Sastry said. “To protect the grid and help the EV industry thrive, we must accommodate these EVs in a smart way, and that’s what we hope to achieve.”

The EV smart charger allows users to customize their charging, with the ability to weight preferences for carbon-free energy, cost, charge speed, and battery health. Credit: Allison Carter

The revolutionary system allows for cheaper, carbon-free charging and aims to reduce the burden on the electric grid as more EVs enter the roadway.

New Smart Charger May Pave the Way for More EVs

As the world grapples with climate change and environmental degradation, the Dutch automotive industry is pioneering efforts in sustainable mobility. 

The Road to Sustainable Mobility in the Netherlands and Europe

We are pleased to introduce the latest edition of the <a href="https://www.raivereniging.nl/en/sections/rai-automotive-industry-nl/" target="_blank" rel="nofollow">RAI Automotive Industry NL</a> report, which provides an in-depth exploration of the Dutch automotive sector's transformative trajectory. This sector, situated at the nexus of rapid technological advancements and pressing global challenges, exemplifies a model of innovation, sustainability, and resilience in a highly competitive international landscape.This issue covers core themes: smart and green mobility, sustainable manufacturing, human capital development, design and materials, and internationalization. Each of these pillars underscores the industry's commitment to integrating advanced technologies into mobility solutions, driving the future of transportation with a focus on efficiency, safety, and sustainability.Below you can read an excerpt of one of the featured articles. Or download the full report for free here.&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI4NjM0MzQ5NTE0LXJhaSBlbWFpbC5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib">&nbsp;<iframe id="JotFormIFrame-242823280704453" title="2024 RAI Dutch Automotive Industry Magazine" allowtransparency="true" src="https://form.jotform.com/242823280704453" frameborder="0" style="min-width:100%;max-width:100%;height:590px;border:none;" scrolling="no" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true">&nbsp;&nbsp; </iframe>&nbsp;International collaboration is a cornerstone of RAI Automotive Industry NL’s strategy for driving technological advancement and market expansion. The global automotive industry is highly interconnected, with innovation and market trends often emerging from various parts of the world. RAI Automotive Industry NL ensures that Dutch companies remain at the forefront of these developments by actively cultivating international relationships, assisting members with international missions, and providing data-driven market research and business intelligence from the global automotive industry.&nbsp;<h2 dir="ltr">Partnerships Drive Innovation Between The Netherlands and the World&nbsp;</h2>A major focus for RAI Automotive Industry NL is building relationships with automotive and tech firms worldwide, which will assist in driving innovation and enhancing technological capabilities within the Dutch automotive sector.&nbsp;“The Dutch Automotive industry doesn’t contain the big brands as OEMs, we are more of a supplier industry. However, when you look at our total turnover, it’s about 30 billion euros, which is quite substantial. This industry supports approximately 70,000 jobs, making it very important. That’s why we focus heavily on internationalization, with 90% of our total turnover coming from exports. We are truly dependent on the global market.”<h2 dir="ltr">Export Promotion and Support for Dutch Automotive Companies&nbsp;</h2>One way RAI Automotive Industry NL supports members in accessing international collaboration is by assisting them in meeting and building relationships with key players worldwide via international trade missions and delegations.&nbsp;“The automotive mobility world faces similar challenges in our focus countries: France, Germany, Sweden, and the United States. We are all working on safety, a greener automotive ecosystem, and more. What makes building these partnerships even more enjoyable is the cultural exchange. It’s so valuable to have these global connections.”These efforts are crucial in helping companies navigate global markets, establish business relationships, and stay competitive. RAI’s activities can be divided into three categories:<h3 dir="ltr">Trade and Innovation missions&nbsp;</h3>RAI organizes trade- and innovation missions around the latest technology advancements. Missions attract many participants and offer the possibility of visiting many international companies and institutions. The missions aim to connect Dutch start-ups, scale-ups, SMEs, corporates, governments, and knowledge institutions with international ecosystems and partners. These missions are specifically interesting to those who want to enter foreign markets with smart and sustainable mobility technology, like new battery solutions and new materials, or wish to do more business there.&nbsp;Businesses that operate internationally tend to be more productive, innovative, and successful. By participating in trade or innovation missions, entrepreneurs can expand their networks and enhance their international opportunities.<h3 dir="ltr">Collective booth at international trade fairs&nbsp;</h3>For those wanting to exhibit at prestigious international trade fairs, RAI offers a joint platform for innovation and networking. RAI members can join the NL Pavilion by reserving a space within the exhibition area. This is particularly attractive for start-ups, scale-ups, and SMEs who cannot afford a pavilion on their own. The pavilion has an open, representative appearance with recognizable, strong NL branding. RAI takes over the complete preparation regarding the stand construction on behalf of exhibitors. Participants can focus on presenting themselves professionally and use the collective space with a bar area and catering. RAI also organizes programs for international delegations in the pavilions. In addition, participants benefit from joint promotional activities that increase traffic to the pavilions. RAI will be present at shows like the IAA, Automechanika in Germany, Solutrans, EQUIP Auto, and the Paris Motor Show in France.&nbsp;“At RAI, we believe that fostering international collaboration is the key to unlocking cutting-edge advancements in the automotive industry.”&nbsp;Bram Hendrix, RAI Program Manager for Internationalization.<h3 dir="ltr">Co-innovation days&nbsp;</h3>RAI organizes co-innovation days that serve as a platform for fostering collaboration and synergy between The Netherlands Automotive and Mobility industry and OEM and TIER1 companies from the international industry. These events, held several times a year, aim to facilitate the exchange of knowledge, innovation, and expertise to drive advancements in these areas and promote mutual growth and development. In the past, co-innovations days have been organised at and with leading companies such as Renault, Continental, and Vitesco. The goal is to facilitate exchange between the innovation departments of companies.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI4NTc0NDI0NjA5LUhvbGxhbmQgUGF2aWxpb24gMS5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"><h2 dir="ltr">RAI’s Partner Network: A Key Player in Automotive Industry Intelligence&nbsp;</h2>RAI gathers market intelligence and conducts research for the Dutch automotive industry by fostering strong relationships with its network of companies and embassy networks. Their member network serves as a rich source of insights, helping to navigate the ever-changing automotive industry landscape.&nbsp;RAI collaborates with embassy networks, including innovation attachés, to gain deeper insights into specific focus countries. The Innovation Attachés provide an overview of scientific and technological developments in their respective regions and have an important trendwatching role. RAI also partners with other cluster organizations, which are groups of interconnected businesses in a particular industry or location. This collaboration allows for the sharing of knowledge and resources, enhances market research capabilities, and fosters collective growth.&nbsp;RAI’s strategic approach to understanding automotive industry trends involves concentrating on a specific group of countries, ensuring a deeper comprehension of these markets. This approach underscores RAI’s commitment to driving informed and targeted advancements in the automotive sector. RAI gathers intelligence most relevant to Dutch companies seeking international partnerships and trade opportunities.<h2 dir="ltr">RAI Automotive Industry NL - Driving Global Automotive Innovation Forward&nbsp;</h2>RAI Automotive Industry NL plays a crucial role in propelling the Dutch automotive industry to the forefront of global advancements. By fostering a collaborative environment and international partnerships, RAI empowers Dutch companies to access global expertise and markets and helps them to drive innovation and navigate a complex international landscape.&nbsp;Collaboration with international partners allows Dutch companies to stay at the cutting edge of technology, contributing to the development of next-generation vehicles and mobility solutions. By connecting Dutch companies with international partners and markets, RAI facilitates export growth, strengthens the Dutch automotive industry’s global footprint, and secures its position in the global supply chain. International partnerships open doors for Dutch companies and help them access a wider pool of talent and expertise, allowing them to build stronger and more diverse teams.&nbsp;<iframe id="JotFormIFrame-242823280704453" title="2024 RAI Dutch Automotive Industry Magazine" allowtransparency="true" src="https://form.jotform.com/242823280704453" frameborder="0" style="min-width:100%;max-width:100%;height:590px;border:none;" scrolling="no" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true">&nbsp;&nbsp; </iframe>&nbsp;

International collaboration is a cornerstone of RAI Automotive Industry NL’s strategy for driving technological advancement and market expansion.

RAI Automotive Industry Global Collaborations

The Dutch automotive industry is one of the frontrunners in today’s smart mobility revolution, driving innovations that are set to redefine transportation on the European and global front. 

Smart Mobility in Action: The Netherlands' Digitalized Automotive Industry

We are pleased to introduce the latest edition of the <a href="https://www.raivereniging.nl/en/sections/rai-automotive-industry-nl/" target="_blank" rel="nofollow">RAI Automotive Industry NL</a> report, which provides an in-depth exploration of the Dutch automotive sector's transformative trajectory. This sector, situated at the nexus of rapid technological advancements and pressing global challenges, exemplifies a model of innovation, sustainability, and resilience in a highly competitive international landscape.This report covers core themes: smart and green mobility, sustainable manufacturing, human capital development, design and materials, and internationalization. Each of these pillars underscores the industry's commitment to integrating advanced technologies into mobility solutions, driving the future of transportation with a focus on efficiency, safety, and sustainability.As Dennis van Well, Chairman of the Board of RAI Automotive Industry NL, notes in his foreword, the Dutch automotive sector is characterized by its dedication to excellence and forward-thinking solutions. This magazine captures the dynamic journey of the industry, showcasing its ability to integrate advanced digital technologies in mobility solutions, from autonomous driving to intelligent traffic management systems, all aimed at improving safety, efficiency, and convenience on the roads.Central to this transformation is the commitment to sustainable practices. Dutch manufacturers are leading the way in adopting renewable energy, circular economy principles, and smart manufacturing technologies to reduce environmental impact while maximizing productivity and quality. This approach aligns with the broader goal of ensuring a sustainable future for the automotive sector in the Netherlands and beyond.<h3 id="isPasted">This industry report is a must-read for anyone interested in the future of mobility, sustainability, and innovation in the automotive industry.</h3>Download the full report here:<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI4NTY1MTc1MjIxLXJhaSBlbWFpbC5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"><iframe id="JotFormIFrame-242823280704453" title="2024 RAI Dutch Automotive Industry Magazine" allowtransparency="true" src="https://form.jotform.com/242823280704453" frameborder="0" style="min-width:100%;max-width:100%;height:590px;border:none;" scrolling="no" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true">&nbsp; </iframe>&nbsp;The Dutch Automotive industry’s success is not solely driven by technological innovation. The Dutch automotive workforce, characterized by its diversity and talent, is the beating heart of this success. Continuous learning, inclusivity, and collaboration are vital elements that ensure the industry remains agile, adaptable, and ready to meet future demands. The stories shared in this edition highlight how teams across the sector are pushing boundaries, driving excellence, and fostering a culture of growth and development.Furthermore, the Dutch automotive industry’s deep-rooted tradition of international collaboration and strong trade relationships is a cornerstone of its global influence. As Van Well emphasizes, these international connections are critical for maintaining the industry’s competitive edge on the global stage. The magazine explores the strategic importance of export activities and highlights the collective efforts of Dutch companies to expand their reach, collaborate across borders, and contribute to the global automotive landscape.This industry report invites readers to dive deep into the key achievements, projects, and innovations shaping the future of mobility. Whether through advancements in lightweight materials, electric mobility solutions, or smart manufacturing technologies, the Dutch automotive industry is committed to pioneering sustainable, intelligent, and globally competitive solutions. As the world continues to face unprecedented challenges, the industry remains a beacon of innovation, driving the future of mobility forward.In the following report, you'll find remarkable stories of collaboration, technological breakthroughs, and visionary thinking that define the Dutch automotive industry's transformative journey. Together, the industry and its stakeholders are shaping a future where mobility is smarter, safer, and more sustainable for all.<h3>Read excerpts from key chapters of the report here:</h3><h2><a href="https://www.wevolver.com/article/sustainable-and-smart-manufacturing-enabling-a-competitive-dutch-automotive-industry" target="_blank" rel="noopener noreferrer">1. Sustainable and Smart Manufacturing Enabling a Competitive Dutch Automotive Industry</a></h2><h2><a href="https://www.wevolver.com/article/driving-innovation-human-capital-in-the-dutch-automotive-industry/draft">2. Driving Innovation: Human Capital in the Dutch Automotive Industry</a></h2><h2><a href="https://www.wevolver.com/article/smart-mobility-in-action-the-netherlands-digitalized-automotive-industry">3. Smart Mobility in Action: The Netherlands' Digitalized Automotive Industry</a></h2><h2><a href="https://www.wevolver.com/article/rai-automotive-industry-global-collaborations">4. RAI Automotive Industry Global Collaborations</a></h2><h2><a href="https://www.wevolver.com/article/design-and-materials-in-the-dutch-automotive-industry-innovations-and-future-directions/draft">5. Design and Materials in the Dutch Automotive Industry: Innovations and Future Directions</a></h2><h2><a href="https://www.wevolver.com/article/the-road-to-sustainable-mobility-in-the-netherlands-and-europe">6. The Road to Sustainable Mobility in the Netherlands and Europe</a></h2>Download the full report here.&nbsp;<iframe id="JotFormIFrame-242823280704453" title="2024 RAI Dutch Automotive Industry Magazine" allowtransparency="true" src="https://form.jotform.com/242823280704453" frameborder="0" style="min-width:100%;max-width:100%;height:590px;border:none;" scrolling="no" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true">&nbsp; </iframe>&nbsp;

The RAI Dutch Automotive Indusry Report 2024, focuses on key themes within the Dutch automotive industry, particularly emphasizing innovation, sustainability, and internationalization. 

Dutch Automotive Industry Report

A multi-institutional research team led by Georgia Tech’s <a href="https://www.mse.gatech.edu/people/hailong-chen" target="_blank">Hailong Chen</a> has developed a new, low-cost cathode that could radically improve lithium-ion batteries (LIBs) — potentially transforming the electric vehicle (EV) market and large-scale energy storage systems.&nbsp;“For a long time, people have been looking for a lower-cost, more sustainable alternative to existing cathode materials. I think we’ve got one,” said Chen, an associate professor with appointments in the George W. <a href="https://www.me.gatech.edu/" target="_blank">Woodruff School of Mechanical Engineering</a> and the <a href="https://www.mse.gatech.edu/" target="_blank">School of Materials Science and Engineering</a>.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1728519667694-Zhantao+sly+smile+device.jpg" style="width: 100%px;" class="fr-fic fr-dib">Zhantao Liu with the new low-cost cathode that could revolutionize lithium-ion batteries and the EV industry. Photo by Jerry GrilloThe revolutionary material, iron chloride (FeCl3), costs a mere 1-2% of typical cathode materials and canstore the same amount of electricity. Cathode materials affect capacity,&nbsp;energy, and efficiency, playing a major role in a battery’s performance, lifespan, and affordability.“Our cathode can be a game-changer,” said Chen, whose team <a href="https://www.nature.com/articles/s41893-024-01431-6" target="_blank">describes its work in Nature Sustainability</a>. “It would greatly improve the EV market — and the whole lithium-ion battery market.”First commercialized by Sony in the early 1990s, LIBs sparked an explosion in personal electronics, like smartphones and tablets. The technology eventually advanced to fuel electric vehicles, providing a reliable, rechargeable, high-density energy source. But unlike personal electronics, large-scale energy users like EVs are especially sensitive to the cost of LIBs.&nbsp;Batteries are currently responsible for about 50% of an EV’s total cost, which makes these clean-energy cars more expensive than their internal combustion, greenhouse-gas-spewing cousins. The Chen team’s invention could change that.<h2>Building a Better Battery</h2>Compared to old-fashioned alkaline and lead-acid batteries, LIBs store more energy in a smaller package and power a device longer between charges. But LIBs contain expensive metals, including semiprecious elements like cobalt and nickel, and they have a high manufacturing cost.&nbsp;So far, only four types of cathodes have been successfully commercialized for LIBs. Chen’s would be the fifth, and it would represent a big step forward in battery technology: the development of an all-solid-state LIB.Conventional LIBs use liquid electrolytes to transport lithium ions for storing and releasing energy. They have hard limits on how much energy can be stored, and they can leak and catch fire. But all-solid-state LIBs use solid electrolytes, dramatically boosting a battery’s efficiency and reliability and making it safer and capable of holding more energy. These batteries, still in the development and testing phase, would be a considerable improvement.&nbsp;As researchers and manufacturers across the planet race to make all-solid-state technology practical, Chen and his collaborators have developed an affordable and sustainable solution. With the FeCl3 cathode, a solid electrolyte, and a lithium metal anode, the cost of their whole battery system is 30-40% of current LIBs.&nbsp;“This could not only make EVs much cheaper than internal combustion cars, but it provides a new and promising form of large-scale energy storage, enhancing the resilience of the electrical grid,” Chen said. “In addition, our cathode would greatly improve the sustainability and supply chain stability of the EV market.”<h2>Solid Start to New Discovery</h2>Chen’s interest in FeCl3 as a cathode material originated with his lab’s research into solid electrolyte materials. Starting in 2019, his lab tried to make solid-state batteries using chloride-based solid electrolyteswith traditional commercial oxide-based cathodes. It didn’t go well — the cathode and electrolyte materials didn’t get along.&nbsp;The researchers thought&nbsp;a chloride-based cathode could provide a better pairing with the chloride electrolyte to offer better battery performance.“We found a candidate&nbsp;(FeCl3)&nbsp;worth trying, as its crystal structure is potentially suitable for storing and transporting Li ions, and fortunately, it functioned as we expected,” said Chen.Currently, the most popularly used cathodes in EVs&nbsp;are oxides and&nbsp;require a gigantic amount of costly nickel and cobalt, heavy elements that can be toxic and pose an environmental challenge. In contrast, the Chen team’s cathode contains&nbsp;only&nbsp;iron (Fe) and chlorine (Cl)—abundant, affordable, widely used elements found in steel and table salt.In their initial tests, FeCl3 was found to perform as well as or better than the other, much more expensive cathodes. For example, it has a higher operational voltage than the popularly used cathode LiFePO4 (lithium iron phosphate, or LFP), which is the electrical force a battery provides when connected to a device, similar to water pressure from a garden hose.&nbsp;This technology may be less than five years from commercial viability in EVs. For now, the team will continue investigating FeCl3 and related materials, according to Chen. The work was led by Chen and postdoc Zhantao Liu (the lead author of the study). Collaborators included researchers from Georgia Tech’s Woodruff School (Ting Zhu) and the <a href="https://eas.gatech.edu/home" target="_blank">School of Earth and Atmospheric Sciences</a> (Yuanzhi Tang), as well as the <a href="https://www.ornl.gov/" target="_blank">Oak Ridge National Laboratory</a> (Jue Liu) and the <a href="https://uh.edu/" target="_blank">University of Houston</a> (Shuo Chen).“We want to make the materials as perfect as possible in the lab and understand the underlying functioning mechanisms,” Chen said. “But we are open to opportunities to scale up the technology and push it toward commercial applications.”CITATION: Zhantao Liu, Jue Liu, Simin Zhao, Sangni Xun, Paul Byaruhanga, Shuo Chen, Yuanzhi Tang, Ting Zhu, Hailong Chen. <a href="https://www.nature.com/articles/s41893-024-01431-6" target="_blank">“Low-cost iron trichloride cathode for all-solid-state lithium-ion batteries.” Nature Sustainability</a>.

Hailong Chen and Zhantao Liu present a new, low-cost cathode for all-solid-state lithium-ion batteries. Photo by Jerry Grillo

A research team led by Georgia Tech’s Hailong Chen has developed a low-cost iron chloride cathode for lithium-ion batteries, which could significantly reduce costs and improve performance for electric vehicles and large-scale energy storage systems.

New Battery Cathode Material Could Revolutionize EV Market and Energy Storage

From the days when ICE cars saw minor updates every three years and major redesigns every five, we’ve shifted to an era where new EV models are released annually. The rapid evolution of electric vehicles is not only energizing the market, but also intensifying competition among manufacturers.EV manufacturers need to innovate more quickly than ever to stay competitive in a market that’s expected to grow rapidly. According to<a href="https://www.grandviewresearch.com/industry-analysis/electric-powertrain-market" target="_blank">&nbsp;Grand View Research</a>, the global electric powertrain market was valued at $83.30 billion in 2022 and is projected to grow at a compound annual growth rate (CAGR) of 15.3% through 2030.<h2 dir="ltr">Manufacturing Challenges in EV Motors, Batteries, and ECUs</h2>At the heart of this rapid shift towards electric vehicles are three critical components: EV motors, batteries, and ECUs (Electronic Control Units). These elements form the backbone of every electric vehicle, powering its movement, optimizing energy efficiency, and managing complex operations. However, as the industry grows, so do the manufacturing challenges associated with these components.<h3 dir="ltr">EV Motors</h3>The design of EV motors is crucial for efficiency. Manufacturers now use thinner stamped lamination sheets (between 0.15 mm and 0.3 mm) to reduce power consumption, but producing these sheets requires extreme precision, especially when handling intricate profiles and sharp corners. Additionally, the need for lightweight materials and complex cooling systems to prevent overheating further complicates motor manufacturing. For mold makers, these factors demand high accuracy to ensure performance and keep assembly costs low.<h3 dir="ltr">Batteries</h3>Batteries serve as the heart of every EV, where power storage and management are critical to vehicle performance. Several production challenges arise:<ul><li dir="ltr">Efficient cooling systems are needed to prevent overheating during use.</li><li dir="ltr">Precise use of materials such as silicon carbide and ceramics is required for durability and heat resistance.</li><li dir="ltr">Perfectly sealed shields are essential to prevent leaks and sediments, which can compromise battery efficiency and safety.</li><li dir="ltr">The growing demand for smaller, lighter battery designs calls for highly accurate mold tooling and efficient production methods.</li></ul><h3 dir="ltr">ECUs (Electronic Control Units)</h3>These units manage critical functions such as power distribution and motor control. Producing intricate micro molds for ECUs is a significant challenge, as even small deviations can affect performance and safety. Manufacturers must ensure precision and consistency, particularly in customized production.<h2 dir="ltr">How Rapid Prototyping Solves These Manufacturing Challenges?</h2>Automotive Manufacturers need solutions that increase efficiency, reduce costs, and allow for greater customization. Rapid prototyping has become a key tool to address these challenges.<ul><li dir="ltr" style="font-weight: bold;">Digital Manufacturing and Quality Control</li></ul>Rapid prototyping uses advanced digital manufacturing techniques to ensure precise production of complex components like thinner stamped lamination sheets for EV motors. By leveraging 3D printing and CNC machining, manufacturers can quickly create and test motor designs, optimizing for both efficiency and durability. This process allows for rapid iteration of complex cooling systems to prevent overheating, ensuring that all parts meet the required specifications.<ul><li dir="ltr" style="font-weight: bold;">Low-Volume, High-Customization Production</li></ul>Battery production often requires customized solutions for challenges like efficient cooling and ensuring perfect seals. Rapid prototyping enables manufacturers to produce small batches of custom battery modules or cooling components at a lower cost. This flexibility allows for frequent design adjustments to meet the evolving demands for smaller, lighter batteries without costly retooling or manual interventions. It also ensures that material precision and sealing are tested and verified before large-scale production.<ul><li dir="ltr" style="font-weight: bold;">Supplier Integration for Streamlined Production</li></ul>For EV manufacturers, working with a single supplier from prototype to full-scale production simplifies the process. Rapid prototyping allows seamless supplier integration, reducing the time and costs associated with switching suppliers. This ensures consistent quality and faster production, especially when developing critical components like motor housings and battery enclosures.<ul><li dir="ltr" style="font-weight: bold;">&nbsp;Accelerated Time-to-Market</li></ul>In ECU development, where micro molds with extreme precision are essential, rapid prototyping accelerates the time-to-market by allowing manufacturers to quickly design, test, and refine intricate components like ECU casings and micro connectors. This ability to rapidly iterate and test designs ensures that production can proceed without long delays, meeting the stringent requirements for safety and performance in the fast-evolving EV market.<h2 dir="ltr">RPWORLD’s On-demand Manufacturing Solutions for EV Component Innovation</h2>RPWORLD offers a wide range of manufacturing services, including CNC machining, injection molding, vacuum casting, and a variety of finishing options, providing automotive customers the flexibility to select the best methods for developing and producing components. Whether for traditional ICE vehicles or EVs, our services enable rapid prototyping with the highest precision and shortest lead times. Our expertise in electric vehicle component development is extensive, offering specialized solutions for motors, batteries, and ECUs, such as:<ul><li dir="ltr">Precision motor housings and lamination components for optimal efficiency</li><li dir="ltr">High-quality battery pack enclosures and cooling system components</li><li dir="ltr">Custom-designed battery module connectors and management system housings</li><li dir="ltr">Detailed ECU casings and intricate micro connectors for zonal control units</li><li dir="ltr">Thermal management parts for both battery and ECU systems to ensure efficient heat dissipation</li></ul>As the automotive industry continues to shift toward electric vehicles, RPWORLD is proud to serve as a trusted partner, providing rapid prototyping solutions that help drive innovation and accelerate the transition to an all-electric future.<a href="https://www.rpworld.com/en/about-us/contact-us/" target="_blank">&nbsp;Let’s work together</a> to bring your EV projects to life.

From the days when ICE cars saw minor updates every three years and major redesigns every five, we’ve shifted to an era where new EV models are released annually. The rapid evolution of electric vehicles is not only energizing the market, but also intensifying competition among manufacturers.

4 Ways Rapid Prototyping Accelerates Innovation in New Energy Vehicles

Understanding the theoretical principles, real-life implementations, maintenance, and  preventive measures for open and closed circuits and navigating the differences between open circuit vs short circuit

Open Circuit vs Short Circuit: Core Differences between Open and Closed Circuit

<a href="http://www.duraauto.com/" target="_blank" id="isPasted">DURA Automotive Systems</a> is a global automotive supplier headquartered in Auburn Hills, Michigan, specializing in the design, engineering, and manufacturing of solutions that drive the evolution of mobility. With a legacy comprising more than 100 years of inspired invention, the company is recognized by leading vehicle manufacturers as the preferred supplier partner for innovative, highly integrated, mechatronic driver control systems, lightweight structural body systems, and a portfolio of precision-manufactured automotive products.<h2 id="isPasted">Ultramodern Manufacturing Facility</h2>The world-class Muscle Shoals factory supplies lightweight EV battery enclosures to the Alabama-based Mercedes-Benz electric battery pack plant in Bibb County. <a href="https://www.durashiloh.com/dura-automotive-celebrates-grand-opening-of-muscle-shoals-high-tech-manufacturing-site-for-ev-battery-enclosures/" target="_blank">The new state-of-the-art manufacturing facility is DURA’s latest investment in vehicle electrification</a>. Previously, DURA launched an advanced lightweight EV structural systems plant in the Czech Republic and opened its second site to manufacture EV battery enclosures in the Republic of North Macedonia.<h2>Imperial Quality and Reliability</h2>The most recent addition to a growing family of worldwide sites is home to cutting-edge manufacturing processes that utilize advanced robotics and proprietary forming and joining technologies to produce lightweight structures for EV battery systems.These structural enclosures, often integral to the vehicle’s chassis, safeguard the EV battery modules and their supporting electrical and thermal management systems. They are made of lightweight material to minimize energy consumption and extend vehicle range and recharge intervals.Consequently, the structures must be precisely manufactured and accurately inspected to ensure they meet the highest quality and reliability standards and contribute to EVs’ overall efficiency, safety, and performance.<h2>&nbsp;Capacity and Flexibility Issues with the CMM</h2>DURA has been using a coordinate measuring machine (CMM) to perform its quality controls – and for good reason. CMMs are the most accurate metrology equipment for quality inspection. However, relying on only one stationary CMM, the metrology department struggled with capacity and flexibility issues. The CMM was often extremely busy with all types of inspection, and the EV battery enclosures had to be brought to the metrology lab for measuring.DURA started looking for additional inspection capability to meet their need for flexibility and mobility, crucial for supporting their growing operations. The company wanted to ensure it sought out the most advanced technology for its precise measurement requirements.<a href="https://www.youtube.com/watch?v=uwaPeHpu-NA" target="_blank">Watch DURA’s Testimonial</a><h2>Trust in the MetraSCAN 3D|BLACK Elite and HandyPROBE</h2>In its quest for new, innovative technology to meet its measurement needs, DURA opted for the Creaform optical CMM <a href="https://www.creaform3d.com/en/optical-3d-scanner-metrascan" target="_blank">MetraSCAN 3D|BLACK Elite</a> and portable CMM <a href="https://www.creaform3d.com/en/metrology-solutions/coordinate-measuring-machines-handyprobe" target="_blank">HandyPROBE</a>, paired with Polyworks. “Creaform and Polyworks have a strong reputation in the 3D measurement industry,” says Branden Head, Metrology Supervisor at DURA. “Our sister facility in Europe had previous experience with Creaform, and the positive feedback weighed heavily on our decision.”<iframe width="640" height="360" src="https://www.youtube.com/embed/uwaPeHpu-NA?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true">&nbsp;</iframe><h2 id="isPasted">High Accuracy Captured on the Shop Floor</h2>The fast and accurate 3D scanner and portable CMM have been engineered to perform highly accurate and repeatable metrology-grade measurements and 3D geometrical surface inspections directly on the shop floor. Equipped with their MetraSCAN 3D or HandyPROBE, the metrology department could capture characteristics at 0.025mm (0.0009 in) accuracy without moving the structures to the metrology lab.This move from touch probing to 3D scanning also enabled DURA to acquire a larger quantity of data quickly, compared to only a few discrete points collected slowly with CMM. In addition, the whole battery enclosure can now be measured in a single setup since the entire part fits into the system’s field of view, eliminating leapfrogs and reducing the measurement time.Used as a mobile measurement station whenever needed, the metrology-grade 3D scanner and portable CMM added intermediate checks directly on the production floor, influencing the overall quality and efficiency of the manufacturing process. Now, more EV battery enclosures can be inspected in less time. In parallel, Creaform’s measuring solutions helped reduce the workload of the traditional CMM, assigning it to critical inspections with tight tolerances.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1723101508625-dura_image_2-1536x759.webp" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">Helpful Training and Fantastic Support</h2>DURA initially received a one-week training course to learn how to operate the 3D scanners and software to their full potential. An additional follow-up training was also offered to improve their measurement results. The engineers described the training as very beneficial and easy to understand.Creaform’s application engineers and technical support were available whenever DURA reached out for questions. Their answers were informative and helpful. “We rely on internal and external resources to ensure that our team fully utilizes the equipment to best serve our facility,” says Mr. Head. “Creaform’s ongoing support has been integral to our growing team.”<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1723101523165-dura_image_3-1536x695.webp" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">Pivotal Increase of Measurement Capability</h2><blockquote>We use the Creaform MetraSCAN 3D and HandyPROBE as portable measurement stations to measure incoming extrusions and get quick scans of the product before it moves forward to a mill to ensure the mill will accept the part. Thanks to Creaform, we have increased our capacity by 75%.-Branden Head, Metrology Supervisor at DURA Automotive</blockquote>The distinct performance obtained with Creaform and Polyworks in DURA’s production environment has confirmed their strong reputation in the 3D measurement industry. “Creaform and its 3D measurement solutions were pivotal for the measurement capability in our facility,” adds Mr. Head. “Our project would have struggled with capacity and mobility without Creaform’s and Polyworks’s technology.”The partnership between DURA and Creaform will certainly continue as the global automotive supplier is now exploring the possibility of integrating Creaform technology into its automated manufacturing process. For sure, the metrology team can always count on Creaform’s dedicated training and support to achieve this next goal.

In its quest for new, innovative technology to meet its measurement needs, DURA opted for the Creaform optical CMM MetraSCAN 3D|BLACK Elite and portable CMM HandyPROBE, paired with Polyworks.

Cutting-Edge Technology and World-Class Manufacturing Factory to Produce Electric Vehicle (EV) Battery Enclosures

Manufacturing cars with strong, lightweight aluminum alloys rather than steel could improve fuel efficiency and extend electric vehicle range, but the material’s instability at high temperatures has held the alloys back from widespread adoption.Creating tiny, reinforcing particles of titanium carbide (TiC) directly inside of molten aluminum results in a stronger, more temperature resistant aluminum-based material called a metal matrix nanocomposite.Up to this point, researchers have not understood how these nanoparticles form, or how they interact with other features in the microstructure, hindering production of the material on an industrial scale.University of Michigan researchers have used a unique high-resolution, 3D x-ray technique to provide a first glimpse into how nanoparticles form, where they are located and how they facilitate further solidification of the molten metal. A paper on the work will be published in the September edition of Acta Materialia.“Most metals start their lifetimes in the liquid state. How they convert from liquid to solid will ultimately determine their microstructures, and hence, their properties and applications,” said <a href="https://mse.engin.umich.edu/people/shahani" target="_blank" rel="noreferrer noopener">Ashwin Shahani</a>, an associate professor of materials science and engineering and chemical engineering at U-M and co-corresponding author of the study.“The study enabled us to understand exactly how the nanoparticles interact with secondary phases in casting, which has been a major challenge for the past half-century.”&nbsp;As nanoparticles are less than 100 nanometers, one ten-thousandth of a millimeter, the researchers used a powerful imaging technique called synchrotron-based x-ray nanotomography to visualize metal microstructure nondestructively in 3D—a feat not possible with conventional imaging approaches.To obtain the visualizations, the researchers created an aluminum composite reinforced with titanium carbide (TiC). That involved a flux-assisted reaction in which a mixture of carbon powder and titanium-bearing salt was reacted with an aluminum melt. 3D reconstructions revealed an unexpected diversity of titanium aluminide (Al3Ti) intermetallic structures, including one that formed directly on TiC nanoparticles larger than 200 nm in diameter. In that case, the Al3Ti crystals grew into an unusual orthogonal plate structure. Meanwhile, the TiC nanoparticles smaller than the 200 nanometer threshold split the Al3Ti intermetallic plates during solidification, forming branched structures.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1722783000473-ezgif-6-9087a81780.gif" style="width: 100%px;" class="fr-fic fr-dib">A magnified view of the “orthogonal plates” of Al3Ti that nucleated on a TiC nanoparticle. The structure measures 10 μm along its longest dimension. Credit: Ashwin Shahani, Michigan Engineering.In addition to imaging, the researchers used phase-field simulations to fill in spatiotemporal “gaps” in the experiments and propose a mechanism for microstructure formation.“We now have evidence that the nanoparticles form well before the intermetallics, and not the other way around, which has important implications regarding the nucleation of the nanoparticles in the first place,” said Shahani.With these results in hand, industry partners can now guide TiC and Al3Ti formation when manufacturing aluminum composites on a large scale—adjusting solidification pathways or alloy chemistries to achieve the desired microstructure and its associated properties.“We have known for a long time that nano-sized particles could improve the performance of metal matrix composites, but the materials could not be produced at scale. We now understand the formation mechanisms that will enable our industry partners to optimize the process for lightweighting applications,” said Alan Taub, a Robert H. Lurie Professor of Engineering and director of the Electric Vehicle Center at U-M and co-corresponding author of the study.Taub is also a professor of materials science and engineering, mechanical engineering and macromolecular science and engineering.This research was funded by the National Science Foundation (grant no. 1762657).Synchrotron-based x-ray nanotomography was performed at the National Synchrotron Light Source II at Brookhaven National Laboratory. Further characterization was done at the Michigan Center for Materials Characterization. &nbsp;&nbsp;

The lightweight material could extend EV range or fuel efficiency once its microstructure is understood.

First 3D visualization of an aluminum nanocomposite for the auto industry

Lithium metal batteries are among the most promising candidates of the next generation of high-energy batteries. They can store at least twice as much energy per unit of volume as the lithium-ion batteries that are in widespread use today. This will mean, for example, that an electric car can travel twice as far on a single charge, or that a smartphone will not have to be recharged so often.At present, there is still one crucial drawback with lithium metal batteries: the liquid electrolyte requires the addition of significant amounts of fluorinated solvents and fluorinated salts, which increases its environmental footprint. Without the addition of fluorine, however, lithium metal batteries would be unstable, they would stop working after very few charging cycles and be prone to short circuits as well as overheating and igniting. A research group led by Maria Lukatskaya, Professor of Electrochemical Energy Systems at ETH Zurich, has now developed a new method that dramatically reduces the amount of fluorine required in lithium metal batteries, thereby rendering them more environmentally friendly and more stable as well as cost-effective.<h2 id="isPasted">A stable protective layer increases battery safety and efficiency</h2>The fluorinated compounds from electrolyte help the formation of a protective layer around the metallic lithium at the negative electrode of the battery. “This protective layer can be compared to the enamel of a tooth,” Lukatskaya explains. “It protects the metallic lithium from continuous reaction with electrolyte components.” Without it, the electrolyte would quickly get depleted during cycling, the cell would fail, and the lack of a stable layer would result in the formation of lithium metal whiskers – ‘dendrites’ – during the recharging process instead of a conformal flat layer.Should these dendrites touch the positive electrode, this would cause a short circuit with the risk that the battery heats up so much that it ignites. The ability to control the properties of this protective layer is therefore crucial for battery performance. A stable protective layer increases battery efficiency, safety and service life.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1721001380090-image.imageformat.1286.1270176615.png" style="width: 100%px;" class="fr-fic fr-dib">If the electrolyte in a lithium metal battery is not properly tuned, this leads to the formation of dendrites (“whiskers”). (Graphic: Nobelprize.org)<h2 id="isPasted">Minimising fluorine content</h2>“The question was how to reduce the amount of added fluorine without compromising the protective layer’s stability,” says doctoral student Nathan Hong. The group’s new method uses electrostatic attraction to achieve the desired reaction. Here, electrically charged fluorinated molecules serve as a vehicle to transport the fluorine to the protective layer. This means that only 0.1 percent by weight of fluorine is required in the liquid electrolyte, which is at least 20 times lower than in prior studies.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1721001399324-image.imageformat.1286.1956524728.png" style="width: 100%px;" class="fr-fic fr-dib">The newly developed method uses fluorinated cations as a vehicle to transport fluorine to the protective layer. As a result, the protective layer remains stable, fluorine use is minimised, production costs are reduced, and the battery is rendered more sustainable. (Graphic: ETH Zurich / Chulgi Nathan Hong)<h2 id="isPasted">Optimised method makes batteries greener</h2>The ETH Zurich research group describes the new method and its underlying principles in a <a href="https://doi.org/10.1039/d4ee00296b" target="_blank">paper</a> recently published in the journal Energy &amp; Environmental Science. An application for a patent has been made. Lukatskaya carried out this research with the help of an SNSF Starting Grant.One of the biggest challenges was to find the right molecule to which fluorine could be attached and that would also decompose again under the right conditions once it had reached the lithium metal. As the group explains, a key advantage of this method is that it can be seamlessly integrated into the existing battery production process without generating additional costs to change the production setup. The batteries used in the lab were the size of a coin. In a next step, the researchers plan to test the method’s scalability and apply it to pouch cells as used in smartphones.<hr><h2 id="isPasted">Reference</h2>Hong CN, Yan M, Borodin O, Pollard TP, Wu L, Reiter M, Gomez Vazquez D, Trapp K, Yoo JM, Shpigel N, Feldblyum JI, Lukatskaya MR: Robust battery interphases from dilute fluorinated cations. Energy &amp; Environmental Science, 2. May 2024, doi:&nbsp;<a href="https://doi.org/10.1039/d4ee00296b" target="_blank">external page10.1039/d4ee00296b</a>

(Photograph: ETH Zurich / Maria Lukatskaya; AI-generated)

A new electrolyte design for lithium metal batteries could significantly boost the range of electric vehicles. Researchers at ETH Zurich have radically reduced the amount of environmentally harmful fluorine required to stabilise these batteries.

Innovative battery design: more energy and less environmental impact

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