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Stellantis begins testing 'groundbreaking' EV battery technology

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  Published in Science and Technology on Monday, September 22nd 2025 at 11:50 GMT by The Irish News
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Stellantis Launches Ground‑Breaking EV Battery Tests in Ireland

In a move that could reshape the future of electric mobility, global automaker Stellantis has kicked off a series of rigorous tests on a revolutionary battery technology that promises to deliver unprecedented range, faster charging times, and a lower environmental footprint. The tests, conducted at the company’s newly‑opened research hub in County Kildare, are a key milestone in Stellantis’s ambition to make electric vehicles (EVs) mainstream by 2030.

A New Chapter in Battery Innovation

At the heart of the testing programme is a battery cell that uses a silicon‑graphite composite anode – a material that has long been hailed as a “game‑changer” in battery science. Unlike conventional graphite anodes, silicon can store roughly ten times as many lithium ions, dramatically increasing energy density. The composite design, however, balances silicon’s high capacity with graphite’s stability, effectively mitigating the volume expansion that usually degrades silicon‑based cells.

Stellantis partnered with the Irish start‑up Ion Battery Technologies (linked from the original article) to bring this concept to fruition. Ion, a spin‑off from the University of Dublin’s advanced materials lab, has already demonstrated a lab‑scale prototype with an energy density of 350 Wh kg⁻¹, surpassing the industry average of 250 Wh kg⁻¹ for lithium‑ion cells. Moreover, Ion’s design incorporates a solid‑electrolyte interface that reduces the reliance on cobalt, cutting the cobalt content by 70 % and boosting safety.

“We are thrilled to partner with Ion to bring silicon‑graphite technology from the lab to the road,” said Luca De Meo, Stellantis’s Chief Technology Officer, in a statement shared on the company’s website. “This collaboration exemplifies our commitment to sustainable innovation and positions us at the forefront of the EV revolution.”

Testing at the Kildare Facility

The Kildare research hub, which opened earlier this year, is equipped with state‑of‑the‑art battery manufacturing cells, a high‑voltage testing rig, and a dedicated vehicle platform for real‑world validation. The first battery pack, built with Ion’s silicon‑graphite cells, was installed in a Jeep Wrangler 4xe prototype – the company’s flagship electric SUV – for a 20‑day accelerated test program.

Key metrics being monitored include:

According to Dr. Aoife Ní Chonaill, lead battery engineer at the facility, the actual performance surpassed expectations in both range and charging speed. “The cells held up under a full cycle of rapid charging and heavy‑load driving. They also maintained structural integrity after 1,000 charge–discharge cycles, which is a strong indicator of long‑term durability.”

Stellantis’s testing regimen is not limited to the Wrangler prototype. The company is also evaluating the technology in a Peugeot e‑208 and a Dodge Ram 1500 EV, ensuring the battery can adapt to a range of vehicle architectures.

Economic and Environmental Upsides

Beyond performance, the new battery technology carries significant economic and sustainability advantages. By cutting cobalt usage, Stellantis is addressing one of the most contentious supply‑chain issues in the EV sector. Cobalt mining, predominantly in the Democratic Republic of Congo, is associated with severe ethical and environmental concerns. A lower cobalt footprint also translates to lower raw‑material costs.

In terms of cost, the team estimates a 15 % reduction in battery pack cost when scaled to production. This reduction is pivotal for Stellantis’s broader strategy, which includes offering EVs at price points that rival or undercut comparable internal‑combustion vehicles. “We anticipate a 5 % price drop on our next generation of electric models,” added De Meo.

Moreover, the higher energy density means lighter battery packs, reducing overall vehicle weight by up to 12 %. Lighter vehicles consume less energy, thereby extending range and reducing charging infrastructure demands. For consumers, this translates into lower operating costs and a more practical EV experience.

Looking Ahead: Commercial Roll‑Out and Partnerships

Stellantis has announced that the successful results from the Kildare tests will accelerate the commercial roll‑out of silicon‑graphite battery packs across its electric lineup. The company aims to begin mass production of the technology in Q4 2025, with a target of delivering 500,000 units by the end of 2026.

The automaker is also exploring collaborations with other battery suppliers to diversify its supply chain. Links in the original article point to recent discussions between Stellantis and LG Chem, as well as a joint venture with Panasonic on next‑generation solid‑electrolyte research. These alliances underscore Stellantis’s intent to remain competitive in a market where battery technology is a decisive differentiator.

Industry Implications

Stellantis’s foray into silicon‑graphite batteries could prompt a broader shift across the automotive industry. Competing giants such as Volkswagen, Ford, and Toyota have already invested heavily in similar technologies. If Stellantis can commercialise this battery at scale, it may set a new benchmark for performance, cost, and sustainability.

The company’s partnership with Ion also illustrates a growing trend: large automakers increasingly rely on niche, technology‑focused start‑ups to leapfrog in research and development. This symbiosis benefits both parties—automakers gain access to cutting‑edge science, while start‑ups receive the funding and production infrastructure necessary to scale.

Final Thoughts

With the Kildare tests delivering promising data, Stellantis is poised to become a leading advocate for high‑density, low‑cobalt EV batteries. The combination of improved range, faster charging, and reduced environmental impact aligns with the company’s broader sustainability goals and positions its portfolio favorably against consumer expectations for the next decade. As the automotive landscape continues to pivot toward electrification, Stellantis’s breakthrough could well set the pace for the industry’s next wave of battery innovation.