How designers can meet the performance and compliance demands of next generation batteries in preparation for updates to the EU’s battery regulations
As electric vehicles (EVs), light means of transport (LMT) and industrial applications accelerate the demand for battery innovation, engineers and manufacturers face dual challenges: how to meet tightening regulations while pushing the boundaries of performance and reliability. A new wave of regulatory updates and AI-powered testing technologies is reshaping the battery development landscape
This article explores how upcoming European Union (EU) battery regulations are driving compliance-focused design decisions, and how the integration of artificial intelligence (AI) in battery testing is enabling faster, smarter and more robust development cycles.
PREPARATION IS KEY
The introduction of the EU Battery Regulation 2023/1542 marked a significant shift in how batteries are designed, labelled and tracked across their entire lifecycle. Effective as of 2023, the regulation enforces stricter controls on environmental impact, raw material sourcing, labelling and digital traceability.
“The EU launched its New Batteries Regulation to help ensure that future batteries have a low carbon footprint, use minimal substances and require fewer raw materials from non-EU countries,” explained Stephen Holland, quality, health & safety, environmental manager at Accutronics, an Ultralife company, in a recent thought piece. “The regulation is all-encompassing, covering everything from raw material sourcing to safe disposal.”
One of the most immediate implications for manufacturers is the requirement for CE marking and detailed labelling. Since August 18, 2024, all batteries must display a CE mark, and by August 2026, additional information including weight, category, origin and hazardous substance content, must also be clearly marked.
In his article, Holland notes the challenge this poses for manufacturers: “If manufacturers are now required to list information as extensive as extinguishing agents, the label size will inevitably need to increase, even if the product stays the same. For example, many of our products come in a standard size, so we will need to rethink how we can present this information while complying with the updated guidance.”
BATTERY PASSPORTS
Perhaps the most forward-looking element of the new regulation is the mandatory battery passport, accessible via a QR code, for LMT, EV and large industrial batteries (≥2 kWh) starting February 18, 2027. The digital passport will contain up to 28 pieces of information about the battery’s specifications, compliance and lifecycle.
“The QR code must be visible, high-contrast and indelible, either printed or engraved on the battery itself – or, if size prohibits, on the packaging or documentation,” Holland says. But the details on implementation remain indistinct: “The current guidance is still vague on how the new QR requirements will be implemented… including what will be purely accessible, accessible only to notified bodies, and so on.”
This push for digitalisation aligns with a broader trend towards batteries no longer being considered just hardware, but data-rich assets that require traceability, intelligent testing and lifecycle insights. This is where AI comes in.
AI-POWERED BATTERY TESTING
As battery systems become more complex and regulatory scrutiny increases, traditional methods for testing and designing batteries are no longer sufficient. Recognising this, Monolith, a leading AI software company for engineering teams, has partnered with UK-based battery testing firm CamMotive to revolutionise how EV batteries are tested and validated.
“Our partnership with Cam Motive has the potential to make EV battery development faster and more efficient,” says Dr Richard Ahlfeld, CEO and founder of Monolith. “Training machine learning models with robust, real-world date is what makes AI truly effective.”
At the core of the collaboration is a hybrid modelling approach which combines physics-based simulations with machine learning techniques to detect anomalies during battery testing. This enables engineers to identify complex failure modes that might be missed by traditional rule-based methods.
“Monolith’s AI technology allows us to use our state-of-the-art test facility more efficiently while generating higher-quality results,” adds Bruce Campbell, director of CamMotive. “The insights we gain through this collaboration will help us detect potential issues earlier, streamline workflows, and enable our engineers to focus on delivering valuable data analysis for our customers.”
SCALING INSIGHT WITH APPLIED AI
Using Monolith’s AI-powered Anomaly Detector and Next Test Recommender tools, CamMotive is already exploring how AI can reduce the need for physical testing by identifying likely points of failure before they occur. In addition to saving time, this shift in approach aligns directly with the regulatory demand for digital traceability and earlier fault detection.
Monolith’s platform allows engineers to reuse and learn from historical test data, enabling faster development cycles without compromising quality. “The platform analyses and learns from this information, using it to generate accurate, reliable predictions that enable engineering teams to reduce costly, time-intensive prototype testing programmes,” Ahlfeld says.
By integrating Monolith’s AI with CamMotive’s real-world battery datasets, both companies aim to produce higher-quality insights and scalable testing strategies. This integration supports Monolith’s mission to halve product development cycles by 2026, which could be a game-changer for companies facing tight timelines and strict regulatory scrutiny.
BRIDGING REGULATION AND INNOVATION
The combination of regulatory pressure and digital innovation is reshaping the battery development landscape. While companies like Accutronics are ensuring compliance with increasingly complex regulations, Monolith and CamMotive are pioneering how AI can streamline testing and validation.
“Device manufacturers can keep their production on track and adapt their processes ahead of time,” Holland says. “By working with an experience battery partner, you can stay ahead of the curve.”
As the industry looks towards 2026 and beyond, success will depend on a myriad of factors. Next-generation battery design will need to take into account compliance, traceability and intelligence, whether through clearer labelling, digital passports, or AI-driven test validation.
