Nyobolt EV unveils its new fast-charging EV sportscar

Nyobolt has transitioned its high-power density, fast-charging battery technology from the lab to practical application by unveiling its first running Nyobolt EV prototype. This vehicle, designed and engineered with CALLUM, aimed to validate Nyobolt’s battery performance in high-performance scenarios. Additionally, it provided car manufacturers with the opportunity to observe an enhanced customer experience, eliminating inconvenient charging downtime.

Rapid charging that delivers near full charge in minutes

Founded in 2019, Cambridge-based Nyobolt has utilised its next-generation patented carbon and metal oxide anode materials, innovative low impedance cell design, integrated power electronics, and software controls to develop power-dense battery and charging systems. These systems support the electrification of high-uptime industrial and automotive applications, including heavy-duty off-highway trucks, EVs, robotics, and consumer devices requiring high power and rapid recharge cycles.

Initial in-vehicle testing this month, using powerful 350kW (800V) DC fast chargers, confirmed that the Nyobolt EV’s 50Ah 35kWh battery could be charged from 10% to 80% in four minutes and thirty-seven seconds. A full 100% charge enabled the prototype to achieve a range of 155 WLTP miles, which is twice as fast as most of the quickest-charging vehicles available today. Additionally, the first four minutes of charging at a constant current of 500A provided 120 miles of range.

Performance that lasts

Nyobolt’s technology addresses the degradation commonly associated with supercharging lithium-ion batteries. Nyobolt’s 24.5Ah cells have successfully completed over 4,000 full Depth of Discharge (DoD) fast charge cycles, equivalent to over 600,000 miles if utilised in the Nyobolt EV pack, while maintaining over 80% battery capacity. This performance far exceeds the warranties of much larger EV batteries currently in use.

Independent OEM testing verified that Nyobolt’s 2.6Ah cells could achieve over 4,400 cycles with a 12C charge and 1C discharge at 23°C. Importantly, the cell's internal resistance increased by only 50% after 4,400 five-minute charge cycles, which is lower than the industry-accepted end-of-life values for EV cells, typically twice the initial value.

“Despite some OEMs showing fast charge times in the region of 15 minutes, a closer inspection reveals the charge is usually across a limited SOC region specifically chosen to limit the amount of life taken out of the cell; for instance, between 20-80%,” says Nyobolt’s co-founder and CEO, Dr Sai Shivareddy. “Typically, the charge profile will only hold these peak charge levels for a short amount of the charge time. Nyobolt’s low impedance cells ensure we can offer sustainability, stretching out the battery’s usable life for up to 600,000 miles in the case of our technology demonstrator.”

Creating an EV for the enthusiast

The 35kWh battery pack in the Nyobolt EV prototype not only adds miles quickly but also features a compact size, benefiting car manufacturers and motorists by enabling energy-efficient electric vehicles that are more affordable to purchase and operate, and crucially, require fewer resources to manufacture.

The Nyobolt EV, a sports car weighing only 1,250kg, exemplifies the potential for the automotive industry to produce lighter, better-handling sports cars using Nyobolt's technology. “We can enable OEMs to build excitement back into the segment, which is literally weighed down by legacy battery technology currently,” says Shane Davies, Nyobolt’s Director of Vehicle Battery Systems.

“Our Nyobolt EV demonstrates the efficiency gains facilitated by our fast-charging, longer-life battery technology, enabling capacity to be right-sized while still delivering the required performance,” adds Davies. “Nyobolt is removing the obstacle of slow and inconvenient charging, making electrification appealing and accessible to those who don’t have the time for lengthy charging times or space for a home charger.”

Scaling production for the future

While the primary purpose of the Nyobolt EV is to showcase and test the battery technology, CALLUM’s team has designed it for potential low-volume production for road or track use. Nyobolt’s battery assembly plans are well-advanced, with the capability for low-volume production within a year, aiming for 1,000 packs by 2025. Nyobolt’s flexible manufacturing model supports volumes of up to two million cells annually. Additionally, once in production, Nyobolt’s battery will meet the EU’s Battery Regulation requirements.

Improving EVs around the globe

The architecture of the Nyobolt EV demonstrates its potential for retrofitting to existing EV platforms, significantly improving charge times and battery cycling life. The battery modules in the Nyobolt EV are cooled using cold plates with a water/glycol mix. The cooling system incorporates an AC compressor and condenser, along with a battery chiller compatible with other performance vehicles, creating a nearly standardised module and battery pack. The limited heat generation, not exceeding 60°C during fast charging or performance driving, is primarily due to the ultra-low impedance cell chemistry.

UK-based battery development

Nyobolt’s technology is based on a decade of battery research by University of Cambridge scientists Professor Clare Grey CBE and Dr Sai Shivareddy, who pioneered cutting-edge supercapacitors. A crucial aspect of Nyobolt’s ability to offer ultra-fast charging without compromising battery life is its low impedance cells, which generate less heat and make managing high-power levels during charging easier. The anode materials in Nyobolt’s lithium-ion battery cells facilitate a faster transfer of electrons between the anode and cathode, enhancing charging efficiency.

Making moves in the automotive space and beyond

Nyobolt has engaged with eight additional vehicle OEMs regarding the adoption of its technology. Beyond automotive applications, Nyobolt’s fast-charging technology is scheduled to be implemented in robotics this year. Other sectors requiring minimal downtime and high productivity, such as heavy-duty commercial vehicles, are also progressing with the integration of this technology.

“Our extensive research here in the UK and US has unlocked a novel battery technology that is ready and scalable right now,” concludes Shivareddy. “We are enabling the electrification of new products and services currently considered inviable or impossible. Creating real-world demonstrators, such as the Nyobolt EV, underlines both our readiness and commitment to making the industries see change is possible.”