Bypassing weak cells could add to EV battery life

What happened

A study led by Chalmers University of Technology suggests that batteries capable of bypassing weak cells could keep electric vehicles on the road longer and lower the total cost over the battery's lifetime; under optimal conditions, lifespan increases by more than 20%. In the researchers' models, the most advanced solution – where each cell can be controlled separately – can extend lifespan by over 20% in some high-voltage vehicles, such as electric trucks and long-range electric cars, though in practice groups of cells are more likely to be controlled together, making that figure a theoretical upper limit. The researchers also modelled a typical 80 kWh car battery with an annual mileage of 12,000 kilometres: a conventional pack is assumed to be replaced after 10 years, in line with current industry practice, while the reconfigurable pack reached the same point after about 11 years, roughly 14 months later, and had a higher residual value because it had aged less. The extra electronics make the technology more expensive up front, but the researchers state that the longer service life and higher residual value can outweigh that additional cost under many realistic conditions; the potential is greatest in high-voltage, long-range vehicles with many series-connected cells. The approach could also affect battery manufacturing by reducing the need for precise cell matching and allowing more packs to get a second life, for example as stationary energy storage.

Impact and signal

Affected components and suppliers

Source and time

Source: Evertiq · 10/8/2026 · View original source