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Battle of Batteries: Engineers Disassemble Tesla and BYD Models and Reveal Details That Could Impact the Electric Vehicle Market in Brazil
Elon Musk’s company and the Chinese giant are competing in the market with distinctly different strategies. A group of German experts published the details of an unprecedented research study that reveals several secrets.
The electric vehicle sector is experiencing a period of intense transformation, where the ability to innovate is crucial to remain competitive. The global rivalry is centered around two major players: Tesla and BYD. Elon Musk’s company was a pioneer and continues to lead in Europe and the United States, although in recent weeks the CEO himself has been contributing to jeopardizing a significant portion of that prestige.
In 2024, BYD surpassed Tesla in production volume. However, this rivalry is not limited to sales numbers: it also involves battery technologies, an essential component that defines both the range and the total cost of an electric vehicle, which can range between 30% and 50% of the final price.
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A Unique Technical Analysis
Recently, a group of German engineers from RWTH Aachen University conducted an innovative study. They disassembled and examined the batteries of two iconic models from each brand: the battery of the Tesla Model Y, specifically the 4680 cell manufactured by Panasonic, and the battery of the BYD Sealion 7, also known in the industry as the Blade Battery. The results of this work, published in the scientific journal Cell Reports Physical Science, provide a deep and detailed insight into the internal workings of these components.
The study focuses on the cells, which are the basic units responsible for converting chemical energy into electrical energy. As these cells determine fundamental vehicle characteristics, such as range and charging time, their analysis is essential for understanding the advancement of electric mobility.
Different Approaches in Battery Design
The RWTH Aachen team carefully analyzed everything from cell design and size to the composition of electrode materials, including electrical and thermal performance. They were also able to infer the assembly processes and estimate the cost of the materials used.
The results show that Tesla seeks to achieve high energy density and outstanding performance, while BYD focuses on a solution that optimizes volume and reduces material costs, which facilitates simpler thermal management.
It is important to highlight that, despite these technical differences, the final price for the consumer is around 50,000 euros for both models, which proves that each approach offers specific advantages, without one completely overshadowing the other. The technologies are so distinct that it is not possible to claim that one is better than the other — they are different concepts. This demonstrates that, in practice, the final performance in the vehicle is comparable, highlighting the diversity of strategies in the market.
Industrial Secret
The high level of secrecy with which both battery manufacturers and electric vehicle manufacturers operate makes it difficult to obtain detailed technical data. Therefore, the method of disassembling and analyzing commercially available components becomes an essential tool to reveal little-known aspects of these technologies.
Although both models use lithium-ion batteries, the chemistries employed are different. Tesla uses the NCM (nickel-cobalt-manganese) composition for its high-performance vehicles, while BYD bets on LFP (lithium iron phosphate) technology, a solution that currently dominates the sector in the hands of Chinese manufacturers.
Each system has its strengths. Tesla’s solution, focused on maximizing performance, requires a more sophisticated cooling system, while BYD’s proposal stands out for its reduced cost and thermal efficiency, particularly interesting under certain usage conditions.
Surprising Discoveries
One of the most surprising discoveries from the study was the absence of silicon in the anodes of the cells, especially in Tesla’s battery, where its presence was expected to increase energy density. Additionally, both manufacturers adopted an unconventional connection technique for the electrode sheets, using laser welding instead of the more common method in the industry, ultrasonic welding.
The results obtained by the German engineers provide a valuable reference for both the scientific community and the automotive industry. The information revealed not only helps to better understand the development strategies of two giants in the sector but also paves the way for the optimization of the next generations of batteries.
Impact on the Brazilian Industry
For Brazilian manufacturers and researchers, this study brings valuable insights into the strategies adopted by two of the largest global players in electric mobility. Brazil, which has been gradually advancing in the electrification of its fleet and seeks to develop a more robust production chain for electric vehicles, can greatly benefit from this information.
With the increasing presence of Chinese companies in the Brazilian market and the alignment of local initiatives with brands like BYD, understanding the design and functioning of LFP batteries in depth is strategic. On the other hand, Tesla’s expertise in using high-energy density NCM cells also offers important lessons for the national industry that seeks to develop competitive solutions for premium vehicles.
Moreover, the trend of using innovative manufacturing processes, such as laser welding, and the choice of materials that facilitate thermal management are aspects that could inspire new lines of research and development in Brazilian technology centers, such as Senai Cimatec, the Technological Park of São José dos Campos, and universities with a tradition in automotive engineering.
It is worth remembering that, in the automotive sector, products that reach the market are generally developed years in advance, but in the electric vehicle segment, the cycles of innovation are faster. Thus, Brazilian manufacturers and suppliers that keep up with these trends quickly will have a better chance of standing out in a market that, despite its challenges, is rapidly growing in the country.
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