Scientists across Europe are developing a new generation of smart, self-healing batteries, a breakthrough that could double the lifespan of electric vehicles (EVs) while reducing their environmental impact. It is backed by the EU-funded PHOENIX initiative.
“Extending battery life will also reduce the carbon footprint of EVs, offering a win-win for both consumers and the environment,” the researchers noted in a press release.
At the heart of the PHOENIX project is a network of embedded sensors that far exceed the capabilities of today’s standard Battery Management Systems (BMS), which primarily monitor temperature, voltage, and current. Instead, the new system can detect more nuanced damage, including physical swelling, heat spikes, and specific gas emissions, all early signs of internal wear and tear.
“Currently, what is sensed is very limited,” explained Yves Stauffer, an engineer at the Swiss Centre for Electronics and Microtechnology (CSEM). “Our goal is to give the battery a brain that can identify problems early and decide when to activate repair.”
Once the battery detects a fault, it can initiate one of several healing methods. These include using targeted heat to restore broken chemical bonds or applying magnetic fields to dissolve dendrites metallic growths that can cause dangerous short circuits. “The idea is that under thermal treatment, some unique chemical bonding will bounce back,” added Liu Sufu, a battery chemist at CSEM.
Beyond longevity, the PHOENIX team is also working to enhance energy density by exploring silicon-based anodes, which can store more energy than traditional graphite. Self-healing features may offer the structural stability needed to make silicon batteries commercially viable, potentially leading to lighter, longer-range EVs.
A key milestone was reached in March 2025, when the team shipped a batch of sensor and repair-trigger prototypes for live testing on battery pouch cells. These trials are expected to validate both the performance and feasibility of the technology.
However, scaling the innovation poses a challenge. Embedding smart sensors into every battery cell increases production costs, a concern the team is actively addressing. “It is exciting to prolong the lifetime of batteries and work on EVs,” said Johannes Ziegler of Germany’s Fraunhofer Institute for Silicate Research.
“It’s all about bringing the parts together.”