With the rapid development of the global electric vehicle market, the penetration rate of new energy vehicles in China has continuously exceeded 50%. The choice of voltage architecture has become a key focus of competition in the technical roadmaps of automakers. Pain points like slow charging and range anxiety are being addressed by a technological revolution triggered by the upgrade of voltage platforms. This is the technological evolution from 400V to 800V and even higher voltage systems in electric vehicles.
As the first-generation voltage platform for the large-scale commercial application of electric vehicles, the 400V system laid the foundation for the electrical architecture of modern EVs. The background of the 400V platform is closely tied to the industrialization process of electric vehicles in the early 21st century. At that time, battery technology, power electronics, and charging infrastructure were all in their early stages of development, making 400V the optimal choice for balancing performance, safety, and cost. This voltage level was well-suited to compatible with traditional industrial power electronics technology and enabled effective integration of existing supply chain resources. Most early best-selling electric models utilized this architecture.
From the Tesla Model S/X and Nissan Leaf to the Chevrolet Bolt (Figure 1), as well as numerous early domestic electric models, the 400V architecture supported the breakthrough of electric vehicles from zero to one. Even today, the 400V platform remains the mainstream choice for most economy electric models, covering a wide range of scenarios from urban commuter cars to commercial logistics vehicles.
Figure 1 several 400V platform electric vehicles (Tesla Model S, Nissan Leaf, Chevrolet Bolt)
The advantages of the 400V platform lie in its technological maturity and cost-effectiveness. After more than a decade of development, the supply chain for the 400V voltage platform has become increasingly mature, and the cost of core components has continued to decrease. Its technological stability has been validated by long-term market use, and the maintenance service system is more comprehensive. For consumers, 400V vehicles have a relatively lower purchase cost, and charging infrastructure is widely available and highly compatible (Figure 2).
Figure 2 charging pile (400V platform)
However, the limitations of the 400V platform have become increasingly apparent as electric vehicles evolve. The most prominent issue is the constraint on charging speed. Since charging power equals voltage multiplied by current, achieving high-power charging within the 400V system requires significantly increasing the current. This, however, leads to thicker and heavier charging cables, increased heat generation, and practical operational difficulties. Currently, typical fast-charging power for 400V platforms is mostly below 150kW. Charging a vehicle with a 60kWh battery to full capacity takes over 40 minutes, making it difficult to meet users' growing expectations for refueling efficiency.
The 800V voltage platform is becoming the new standard for high-end electric vehicles, aiming to fundamentally address the pain point of refueling efficiency in EVs. The emergence of the 800V platform is directly related to the expansion of the EV market and the evolution of user demands. As electric vehicles transition from a niche market to the mainstream, users have developed higher expectations for the overall vehicle experience. Particularly in long-distance travel scenarios, charging speed has become a key factor influencing purchase decisions. The 800V architecture has emerged to address this, increasing voltage to reduce current, thereby enabling high-power charging while avoiding the various issues associated with high current. By 2025, several automakers had launched corresponding products.
The first vehicle to support the 800V high-voltage platform was the Porsche Taycan (Figure 3), launched in 2019. Today, increasingly more electric vehicles support the 800V platform. It's not just sedan models; mid-to-large-size SUVs and even mid-to-large range-extended SUVs are gradually adopting the 800V high-voltage platform. For example, the Leapmotor D19, marketed as "the only 800V large-battery, large five-seat super range-extended SUV," supports 800V ultra-fast charging. Envision AESC's 46-series battery cells supplied for BMW's global electric platform support a full 400-1000V voltage platform, covering vehicle classes from A to D. On the battery front, Sunwoda Power's launched Xinxingyao 2.0 kA extreme fast-charging version, matched with a 1000V high-voltage system platform, can support 1.4 megawatt flash charging.
Figure 3 the first 800V platform electric vehicle (Taycan)
The advantages of the 800V platform are evident. First is the revolutionary improvement in charging speed. Vehicles based on the 800V platform, combined with high-power charging piles, can achieve the experience of "adding 200 kilometers of range with a 5-minute charge," significantly alleviating users' range anxiety. Sunwoda Power's flash-charging battery 4.0 has been iterated to a 12C extreme fast-charging version, reducing single replenishment time to within the 5-minute range (Figure 4). Second is the improvement in energy efficiency. The 800V system halves the operating current at the same power level, thereby reducing line losses and improving energy utilization efficiency, which positively contributes to extending the driving range. The 800V platform also offers the advantage of lightweighting. The reduced diameter of the high-voltage wiring harness helps decrease overall vehicle weight, enhancing both vehicle performance and energy efficiency.
Figure 4 Sunwoda LFP flash charging battery
However, the 800V platform also faces several challenges. The cost issue is the primary concern, as the 800V system requires redesigning all related components including batteries, electric drives, and charging interfaces, with increased voltage withstand requirements leading to higher costs. Charging infrastructure compatibility is another challenge; although 800V vehicles are theoretically compatible with 400V charging piles, they require additional adaptation devices and cannot utilize their high-voltage advantages in such scenarios (Figure 5). Furthermore, grid load cannot be ignored - the widespread adoption of high-power charging places greater demands on regional grid distribution capacity, necessitating intelligent charging management systems to balance the load.
Figure 5 Huawei supercharging pile
As voltage platforms evolve, the requirements for battery testing equipment are increasingly heightened to ensure the safety and reliability of battery systems in high-voltage environments. For 400V systems, testing equipment must accurately evaluate battery performance, capacity, and lifespan, while precisely controlling test conditions such as temperature, humidity, and charge-discharge cycles. The requirements for battery testing equipment for 800V platform electric vehicles are even more stringent. High-precision battery testing systems need to provide accurate measurement capabilities for parameters such as voltage, current, resistance, and capacity. For 800V high-voltage systems, battery testing equipment must perform various tests, including charge-discharge cycles, capacity tests, impedance spectroscopy, and accelerated aging tests. Battery simulators need to meet key technical requirements such as voltage accuracy better than ±1mV and microsecond-level response capability. The technical specifications for bi-directional power supplies used for simulating single cells in Battery Management System testing are particularly crucial for power storage and electric vehicle BMS testing, ensuring BMS reliability in high-voltage environments. Advancements in measurement sensitivity, test automation, and data analysis software for high-precision battery testing systems are vital for the development and quality assurance of 800V platform batteries.
Facing the 400V and 800V platforms, the future electric vehicle market will present a pattern of diversified coexistence, with each having its own development path and market positioning. The future prospects for 400V platform electric vehicles remain broad. Considering the cost advantages and technological maturity, the 400V architecture will maintain an important position in the low-to-mid-end EV market. Especially in the A00 and A0 segment mini EVs and commercial logistics vehicles, where price sensitivity is high and charging needs are relatively straightforward, the 400V platform is the most economical and practical choice. Many plug-in hybrid models will also continue to use the 400V architecture because their battery capacity is relatively small, and decent charging efficiency can be achieved even with the 400V platform.
The future outlook for 800V platform electric vehicles is very optimistic. As technology matures and economies of scale emerge, the 800V architecture will gradually penetrate from high-end models into the mid-range market. By 2030, the penetration rate of the 800V platform in the price segment above 200,000 yuan is expected to increase significantly. Domestic brands like Leapmotor, NIO, and Li Auto have already deployed 800V systems in their higher-priced models. The upgrading of the charging network will also facilitate the adoption of the 800V platform, with the accelerated construction of high-power charging piles providing a better refueling experience for high-voltage platform vehicles.
The prospects for battery testing equipment are closely linked to the development of voltage platforms. As the 800V market expands, the demand for high-precision testing systems will continue to grow. A QYResearch report predicts that the Chinese high-precision battery testing system market will maintain steady growth from 2025 to 2031. Future battery testing equipment will develop towards higher precision, greater efficiency, and stronger automation capabilities, with modular and scalable testing platforms being more favored. Simultaneously, the demand for testing equipment for both 400V and 800V platforms will coexist, meeting the evaluation needs of battery products at different levels.
Currently, the market mainstream is still dominated by the 400V platform, which has higher penetration and applicability. However, with the continuous development of related technologies such as battery technology, charging technology, and battery testing technology, the 800V platform, while maintaining its original advantages, will continuously mitigate its weaknesses, allowing more users to experience the convenience brought by high-voltage platforms. Meanwhile, the 400V platform will also keep evolving, increasing charging current to enhance charging speed while ensuring safety, thereby better complementing the overall electric vehicle charging market.
The lab focuses on solid-state battery research to overcome traditional lithium batteries' safety and energy density issues, supporting environmental sustainability. It develops innovative solid-state electrolytes, refines electrode materials, and investigates ion transfer and interface stability to revolutionize battery technology.
The electric vehicle battery industry is rapidly developing, focusing on technological innovation, market competition, and sustainability. Research hotspots include solid-state batteries, new types of electrolytes, BMS optimization, and recycling technologies. The environmental adaptability, safety, and economic viability of batteries are key research areas, and the industry is expected to undergo more innovation and transformation.
We specialize in battery preparation technology research, focusing on overcoming existing energy storage challenges by innovating in electrode materials, battery chemistry, and manufacturing processes to improve performance, enhance safety, and reduce costs. Sustainability and recycling technologies for batteries are also emphasized to mitigate environmental impacts and foster the growth of green energy.
