Modern EV buyers expect ~500 km of range and 20–30 minute fast charging as standard. Delivering both in a single battery platform means pushing energy density to its limits without sacrificing safety, thermal performance or lifetime.

In this on-demand webinar, Dhammika (Head of Battery Modelling) and Tomas (Product Manager, Embedded) from Breathe walk through how to:

Design high energy density cells using Breathe Simulate
How the Molicel P45B and Tesla 4680 cells behave when scaled across formats
Understand thermal and anode-potential trade-offs at high energy densities
Use adaptive charging to safely unlock fast-charge performance in real vehicles

Watch the webinar replay

What you’ll learn in this session

You will learn:

What EV buyers care about today – McKinsey data shows that 500 km range and 20–30 minute DC fast charging are now baseline expectations.
Why “range added in 10 minutes” is becoming the dominant fast-charge KPI
This metric reflects real driving experience and is much harder to manipulate than 10–80% charge times.
How to design high energy density cells
Using simulation to understand the impact of NP ratio, cathode loading, electrode porosities, thicknesses, and recipe changes.
How the Molicel P45B and Tesla 4680 cells behave when scaled
What increases (capacity, volumetric energy) and what risks grow (thermal gradients, heat flux, resistance).
The thermal and safety trade-offs that emerge at higher energy densities
Including detailed behaviour of anode potentials under fast charging.
How software and real-time estimation expand what hardware can safely deliver
And why adaptive charging can safely reach performance that lookup tables cannot.

Who this webinar is for

Cell design and electrochemistry teams
Battery pack and thermal engineers
EV platform and product owners
Modelling, simulation, and validation engineers

See Breathe Simulate in action

The webinar includes a comparison of Molicel P45B and Tesla-derived 4680 parameters, showing how each cell behaves when evaluated in 4680-scale designs using Breathe Design.

In the demonstration, you’ll see how Breathe Simulate helps you:

Start from a parameterised commercial cell such as the Molicel P45B
Conduct sensitivity analysis on cell parameters
Quantify the impact of parameter variation on performance and degradation
Simulate degradation modes such as LLI and LAM
Evaluate how ageing shifts thermal and fast-charging limits
Translate cell-level behaviour into system-level battery insight

Try Breathe Simulate

Explore documentation

Download the Molicel P45B Breathe Simulate example

Want to go deeper with your own cells?

If you want to evaluate your own cells using this workflow, Breathe offers:

Cell parameterisation
You send 10 cells. Breathe performs teardown, characterisation, parameterisation and validation.
Your cell models then become available inside Breathe Simulate.
Co-design studies
Work with Breathe to build early insight into degradation pathways and their system-level impact, stress-test control strategies against aged cell states and inform system, control, and vehicle-level battery decisions