Monday, August 3, 2026

Why integrated FPC-based cell contact solutions are essential to battery pack manufacturing


Increased battery density is the endgame of all cutting-edge battery design, improvements cannot come at the expense of safety or cost limitations. The question then becomes how to push the envelope in a safe and cost-effective way. Monitoring the state-of-health of cells is at the top of the list of considerations.

Accurately measuring ambient factors like temperature and voltage provides critical data to the BMS. For years, this could be done through discreet wiring, though this method was inefficient, and the quality was lacking. In today’s designs, flexible printed circuit boards (FPCs) are replacing discrete wiring. These FPC-based systems are the newest generation of cell contacting systems. They simultaneously bring down the cost of pack manufacturing and improve reliability in manufacturing and data harnessing.

The quality of data is essential in order to safely maximize energy density. This white paper from Churod Electronics details the hows and whys of FPC-based Cell Contacting Systems and how this cost-effective, yet reliable tool is a key to modern battery pack efficiency.



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char.gy and Devon Council partner on kerbside EV charger trial


Curbside charging (kerbside to our British colleagues) is the solution to the problems faced by EV owners who rely on on-street parking. Curbside chargers are now common sights in London, and they’re spreading to other regions of the UK.

On-street charge point operator char.gy is set to begin a trial of new on-street EV charge points in Devon. The company will deploy 30 new on-street charge points installed across the county. All will be powered by 100% renewable electricity.

The project is supported by the UK government’s Local Electric Vehicle Infrastructure (LEVI) Fund. When the trial is completed, the lessons learned will inform the next phase of installations.

According to Zapmap, the UK had around 87,000 public charging points at 45,000 locations as of late 2025. So far, the lion’s share of these have been installed in urban areas, but they’re starting to be rolled out in larger, rural counties such as Devon.

char.gy operates what it describes as the UK’s fourth largest on-street charging network—it has over 5,000 public charge points currently in operation.

“This trial is an important step in turning LEVI funding into real, usable infrastructure for communities,” said John Lewis, CEO of char.gy. “For many drivers in Devon, access to reliable on-street charging is essential to making the switch to electric. By starting with a focused trial, we can learn what works locally and help lay the foundations for a wider rollout that gives residents confidence to go electric.”

Source: char.gy



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Sunday, August 2, 2026

MAHLE introduces a new range extender engine and a rare earth-free electric motor


Automotive supplier MAHLE has developed a range extender system for heavy-duty trucks that packages a combustion engine and a generator into part of the space an electric truck’s battery would normally occupy. The system is designed to replace about one-third of the battery capacity of a typical electric truck with a compact diesel engine.

The assembly is a self-contained unit: the generator, engine, thermal and fluid management, fuel tank, AdBlue tank and exhaust treatment sit inside one box that drops into existing battery-electric platforms. The high-voltage generator, which features a newly developed oil cooling system, delivers 110 kW continuous and up to 130 kW peak power, and boasts a power density of more than 7 kW per kilogram.The unit’s thermal management system provides 48 kW of high-temperature and 15 kW of low-temperature cooling.

Swapping part of the battery for the range extender cuts the rear axle load by about 400 kg and the total vehicle weight by about 600 kg, MAHLE explains.

MAHLE has also developed a new Contactless Transmitter (MCT) electric motor for the drive axles of heavy commercial vehicles. It uses no permanent magnets and therefore no rare earth elements, which the company says saves up to 3 kg of rare earth magnets per vehicle compared with a benchmark permanent magnet synchronous motor.

The motor is 10% lighter and more efficient than a permanently excited design under real driving conditions, according to MAHLE. It delivers a peak output of 370 kW and torque of over 900 Nm at 3,900 rpm, and reaches about 95% efficiency in the EU’s VECTO simulation cycle.

“Our range extender is the key to disconnecting the market ramp-up of battery-electric trucks from the inadequate pace of infrastructure development,” said Marco Warth, MAHLE’s Vice President of Corporate Research and Advanced Engineering.

Source: MAHLE



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New Mitsubishi Eclipse Sportback EV to offer both J1772 and NACS charging ports


Many automakers are fitting new cars with NACS (SAE J3400) charging ports instead of the more traditional CCS ports. For road trips, this allows drivers to use Tesla Superchargers without an adapter, but most EV owners will need to replace their home chargers if they buy a new NACS-equipped EV.

Mitsubishi is taking a different tack. The 2027 Mitsubishi Eclipse Sportback, an all-new EV that will be launched across North America in the fall of 2026, will offer both a J1772 and a NACS charging port as standard equipment on all models.

Most Charged readers will be conversant with the various charging standards in use today, but for new EV owners, charging may seem like a more complex issue than it is (and good luck getting a car salesperson to explain it). Both the CCS and NACS standards allow both AC (at home) and DC (on the road) charging, but NACS handles both AC and DC charging with the same plug.

Thus, the Mitsubishi Eclipse EV will be able to charge at Levels 1 and 2 using the J1772 plug found on most home chargers and portable chargers, and it will be able to use DC fast charging (at up to 150 kW) or Level 2 charging using the NACS plug.

Source: Mitsubishi Motors North America



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Friday, July 31, 2026

Arnold Clark Charge joins Radius EV charging network


Arnold Clark is a UK chain of car dealerships that was founded in 1954 by the colorful Scottish billionaire businessman of the same name. In 2024, the company got into the public EV charging business, and now operates over 400 chargers—most offering charging speeds of 150 kW—at 60 locations throughout the UK.

Now Arnold Clark Charge has partnered with fueling network Radius, which has some 500,000 subscribers. Radius customers can now access the Arnold Clark Charge network.

“Partnering with Radius allows us to extend the reach of Arnold Clark Charge to even more fleet operators and EV drivers across the UK, while maintaining our focus on delivering a high-quality charging experience,” said Pablo Levi, Group Sustainability Manager at Arnold Clark.

“Arnold Clark Charge’s growing network, combined with its affordable pricing and ultra-rapid charging capability, makes it a valuable addition to the Radius EV network,” said Andy Higgins, EV Network Manager for Radius. “This partnership gives fleet operators and drivers even more choice and coverage across the UK.”

Source: Arnold Clark Charge



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Lectron’s new Nexus Home EV charger line features automotive-grade engineering and validation


EV charging hardware provider Lectron has launched a new line of Level 2 wall-mounted residential EV chargers.

The new Nexus platform is engineered for sustained electrical load, repeated daily use and extended environmental exposure. Lectron developed its Nexus line using engineering, manufacturing and validation processes informed by the company’s OEM automotive programs.

The internal design incorporates automotive-grade power delivery architecture, PCBA layout and thermal management systems informed by Lectron’s OEM automotive programs.

Nexus is available in four configurations. The Nexus 48 A is a hardwired unit designed for permanent installation. The Nexus 40 A is a portable unit that connects to a standard NEMA 14-50 outlet. Both units are available with either SAE J3400 (NACS) or J1772 connectors.

All Nexus models feature a flexible 23-foot 7 AWG cable, and are housed in IP66-rated enclosures for indoor and outdoor installation.

Nexus chargers are certified to UL 2594, UL 2231, UL 2251, and UL 817 standards. Internal validation testing includes thermal cycling from -22° F to 122° F, sustained load operation at rated amperage, connection cycle testing exceeding 10,000 insertions, and impact testing.

“Nexus reflects the engineering and validation standards used across Lectron’s OEM programs and charging hardware,” said Christopher Maiwald, CEO of Lectron. “It is designed for consistent, high-reliability operation under everyday residential charging conditions.”

Source: Lectron



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Thursday, July 30, 2026

What the next generation of EV charging has to look like


The US charging network 2.0—The evolution of a revolution: Part 4
» Read part 1 here: How the biggest US EV charging networks got their starts
» Read part 2 here: How government helped build America’s EV charging market
» Read part 3 here: Why EV charging is still such a hard business

The next phase of EV charging deployment will not be defined simply by adding more pins on a map. It will be defined by whether the industry can add a lot more capacity, faster and more reliably, while giving investors, utilities and site hosts a better path to acceptable returns.

The scale of the buildout is getting harder to ignore

According to the International Energy Agency’s Stated Policies Scenario, US charging networks will need to install 58,000 public chargers per year to stay on a 2030 trajectory based on historical EV-sales trends. That equates to adding 70% more chargers each year than have ever been installed in the US in a single year. The same IEA analysis shows that the US charging market is not keeping pace with EV sales. The ratio of EVs to public chargers climbed from 15:1 in 2016 to 33:1 in 2024. By comparison, the EV-to-charger ratio across the European Union has never exceeded 15:1.

So how can charging networks expand to meet growing EV demand while staying afloat? The signs point in three directions: continued public support, more direct involvement from the companies that keep the lights on, and a rethink of how infrastructure incentives are structured.

Utilities have to matter more

Many utilities across the US already support EV charging through grant, incentive or reduced-rate programs. The Edison Electric Institute tracks hundreds of EV programs that reduce the cost of installation or the price of electricity delivered to vehicles. A few utilities have owned and operated charging stations themselves—Portland General Electric and Kansas City Power & Light are examples—but the broader opportunity is in using utility balance sheets and rate structures to lower deployment risk for private developers.

Several utilities offer make-ready incentives that cover the cost of bringing power to a station, one of the most expensive and unpredictable parts of the project. Others defray equipment costs or discount each kilowatt-hour delivered to an EV. These programs do not just benefit charging developers—they can also help utilities sell more power and fill in some of the valleys when demand is lower and generating assets are underutilized.

Expanding the utilities’ role is critical, according to a recent Transportation Energy Institute report on EV charging infrastructure funding. As the report notes, utilities can provide important relief from costly demand charges and can play a stabilizing role in the business case for charging.

Utilities are not just another group of stakeholders. In many cases they are the only players that can materially reduce interconnection risk, demand-charge pain and upfront power-delivery costs.

Speed matters almost as much as capital

Delays from utilities in getting stations operational once a site is selected can doom profitability. The permitting, equipment-procurement and power-delivery process can still take 6 to 24 months. Utilities are making strides in expediting those steps, but support from regulators to streamline the process and make it more of a partnership would greatly aid the industry.

Delays of months to years can significantly impact the profitability of a station because the payback period is extended. This makes project speed almost as important as project cost. A charger that is waiting on utility work is not just delayed infrastructure. It is stranded capital, delayed revenue and a longer road to investor confidence.

Rethinking incentives around the utilization gap

Pasquale Romano, formerly the President and CEO of Chargepoint, argues that incentives should focus less on simply buying hardware and more on the “utilization gap” that appears during the first years after a new charging site opens. New stations are often unknown to local EV drivers and need marketing, time and word of mouth to get on consumers’ radar.

His suggestion is that government or utility incentives cover the gap between what it costs to operate a station and the revenue it generates during this early period, giving investors more certainty because they “can’t take the utilization risk open-ended.” The incentives could decline over time and even include bonuses if stations exceed projected utilization.

That idea is notable because it treats underutilization as a predictable ramp-up problem rather than as proof that a site was a mistake. In a young market, that difference matters.

The charging industry may need to subsidize not only steel in the ground, but also the time it takes for a new site to become known, trusted and busy enough to pay for itself.

The virtuous cycle the industry is chasing

Interjecting funds that expand the charging network by reducing investor risk creates a virtuous cycle with vehicle sales, according to Electrification Coalition Executive Director Ben Prochazka. More visible and reliable charging gives consumers confidence that there are enough places to plug in, which helps grow EV sales, which then supports more investment in charging.

That is the real test for Charging Network 2.0. The industry has already proven it can build chargers. The next challenge is building a network that is faster to energize, easier to finance, more reliable in operation and better aligned with the pace of EV adoption.


About the authorJohn Gartner has been analyzing and writing about EV infrastructure since 2009. He is the Senior Director at the Center for Sustainable Energy.



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Why integrated FPC-based cell contact solutions are essential to battery pack manufacturing

Sponsored by Churod Electronics. Increased battery density is the endgame of all cutting-edge battery design, improvements cannot come at t...