Project Resilite: New Safe Battery Packs With Improved Energy Density

Battery Technology Project Resilite: New Safe Battery Packs With Improved Energy Density

2025-09-26 By Stefanie Eckardt | Translated by AI 2 min Reading Time

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The EU project Resilite, running until the end of June 2028, focuses on the development of battery packs based on cylindrical cells in thermoplastic housings. These are intended to not only offer higher energy density and efficiency but also excel in terms of safety, temperature resistance, and sustainability of battery packs in electric vehicles. If successfully implemented, the project results are also planned to be utilized in aviation.

In the EU project Resilite, the partners are working on new battery packs based on cylindrical cells in thermoplastic housings, which, if successfully implemented, could also be of interest for aviation.(Image: AI-generated at PEM RWTH Aachen) — In the EU project Resilite, the partners are working on new battery packs based on cylindrical cells in thermoplastic housings, which, if successfully implemented, could also be of interest for aviation.
(Image: AI-generated at PEM RWTH Aachen)

Together with Kautex Textron, the Fraunhofer Institute for High-Speed Dynamics, the Fraunhofer Institute for Structural Durability and System Reliability LBF, the University of Ljubljana, Infineon Technologies, Fundacion Cidetec, Inova+ – Innovation Services, Air Energy Entwicklungs GmbH, and the Turkish electric vehicle manufacturer Togg, the chair "Production Engineering of E-Mobility Components" (PEM) at RWTH Aachen (Germany) is working on efficient and safe battery packs. What is the approach? As part of the project, cylindrical cells in the 4695 format are to be densely packed in a lightweight housing using the cell-to-pack approach. The housing will be made from recycled fiber-reinforced thermoplastic materials. A structurally integrated cell holder in the housing is intended to completely eliminate the need for potting materials. The planned concept aims for an energy density of 99.8 Wh/lb at the pack level. This target value exceeds the current state of the art by more than 14 percent. Thanks to combined indirect cooling solutions integrated into the cell holder of the housing, charging and discharging rates of more than 4.5 C are expected to be achieved.

Prioritizing Safety

The project partners aim to improve fire safety through a soft ventilation concept combined with flame-retardant nanomaterials integrated into the cell holder. To achieve a high level of redundancy for safety measures, advanced diagnostic software will quantify the battery condition using electrochemical impedance spectroscopy (EIS). Model-based SoX estimation algorithms are planned to be implemented on the battery management system to enhance its diagnostic capabilities. The thermal management control will be designed using neural networks via a scenario-based algorithm, thereby increasing the battery's energy efficiency. Thermoplastic materials for the housing will further thermally insulate the battery pack, extending its standby time in cold environments before active heating solutions become necessary. The intended measures and materials are expected to contribute to reducing total lifecycle costs of battery packs while providing a more resilient system than currently available. (se)

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Date: 08.12.2025

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