Cell selection and pack design for fast charging

Electric vehicles (EVs) are rapidly becoming a mainstream choice for consumers worldwide, driven by advances in technology, supportive policy frameworks, and growing environmental awareness. Despite this momentum, a key barrier to broader adoption remains the compromise in driving range compared to internal combustion engine (ICE) vehicles. Under favorable operating conditions, most EVs achieve a maximum range of about 300 miles. While a 15–30 min fast-charging session typically adds roughly 200 miles of range, ICE vehicles can regain full range in about 5 min at a fueling station. Enhancing battery cell performance is therefore critical to shortening recharge duration and increasing energy delivered per charge cycle. This challenge is amplified for larger vehicles, such as trucks and SUVs, where lower aerodynamic and mass efficiency translates to higher energy demand for equivalent range gains. In this work, we investigate how advanced cell chemistry influences battery pack architecture, thermal management, and charging capability. Furthermore, we describe an experimental testbed that has enabled evaluation of multiple fast-charging schemes under controlled conditions. Recently, we successfully demonstrated megawatt-level charging with this laboratory setup, underscoring both the promise and complexity of scaling such solutions for widespread deployment.