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November 2023

SBD Explores: 800V EVs

What are 800V EVs and should
automakers be adopting it?
10-minute Insight
800V architecture is being introduced by vehicle
manufacturers. This new architecture can give automakers asignificant advantage over their competition, specificallyrelated to consumer experience. This comes at a higher build
cost than current 400V architectures, however.
The adoption of 800V architecture is in the early stages and,for the technology to be successful, it will require suitablecharging infrastructure. Infrastructure must also keep pacewith consumer demand for high-speed charging.
In this edition of SBD Explores, we provide a snapshot of thecurrent 800V market and outline the advantages,
disadvantages, and major players in the 800V race.
Target audience
Product planning / Strategy
Engineering / Investing

Focus market(s)Global1

What is happening?
US – Penetration of 800V Chargers

EU – Penetration of 800V Chargers

3.50%

3.50%

3.00%

3.00%

2.50%

2.50%

2.00%

2.00%

1.50%

1.50%

1.00%

1.00%

0.50%

0.50%

0.00%

0.00%

2022 Q2 2022 Q3 2022 Q4 2023 Q1 2023 Q2 2023 Q32022 Q2 2022 Q3 2022 Q4 2023 Q1 2023 Q2 2023 Q3

OEMs with 800V models
AudiGenesis
GMCHyundai
Kia
Porsche2019 Q12020 Q12021 Q1
US2022 Q12023 Q1

800V batteries and systems are alreadyoffered by component manufacturers.
This has enabled some automakers toadopt the technology and bring
800V vehicles to market. Charge
point providers are expanding support
for these types of vehicle by making
800V-capable chargers available.
• In the EU, there is a steady increase inthe availability of 800V charging stations.
In the US, the growth is stagnant.

Number of 800V In-Production Vehicle Models
20181614121086420Key takeaway

2023 Q3• The stagnant growth of 800V chargers inthe US contrasts with the risingavailability of 800V vehicles in theUS. More 800V vehicle models areavailable in the US compared with theEU.
• The range of 800V models available on
the market in China is small. However,
SBD expects this to increase. BYD has astrong presence in the 800V segmentwith their e-platform 3.0 and Xpeng has
released their latest G9 model with 800V
architecture.

AudiHyundaiKia
PorscheEU2

Why does it matter?
Key takeaway

Faster Charging Times

More Power

Low-Current Cable Support

No Additional Hardware Needed

Greater Efficiency andRange

Lighter Components

Lower Cost to Build

400V Architecture

800V Architecture

Charge times are typically current-limited
either due to the capacity of the cables or
the heat generated by the higher currents.

Supports higher power charging due tolower current needed for similar power.

Higher power potential with similar current
profiles and smaller motors.

Can provide more power to the motors forfaster acceleration.

Many high-power chargers use 200A cables,
limiting 400V vehicles to slower-thanexpected charging speeds.

Higher voltage enables the use of lower
current cables. This applies to both charging
and the powertrain.

400V vehicles are already compatible withboth 400V and 800V chargers.

Requires a DC/DC converter to be able tocharge on existing 400V charging
infrastructure.

Heavier components and less energy
recovery potential compared to 800V.
Higher currents produce more heat.

Able to capture more power fromregenerative braking. Less energy lost toheat. Overall lighter build leads to better
efficiency/range.

Current limitations lead to heavier cables,power equipment, and motors being used
due to lower voltage.

Lighter cables, power equipment, andmotors can be used due to high voltage
supporting lower current.

No new architecture required and existinghigh-volume components can be used.

Requires a rework of vehicle architecture
and investment into new electroniccomponents.

There are benefits to moving fromexisting 400V architecture to 800V
architecture. SBD expects that whenOEMs quantify these benefits, it willshow that investment in 800volt technology is justified.
• The main direct impact of 800V
technology to the consumer is fastercharging times. 800V architecture cansupport faster charging times when usedwith 800V capable chargers.
• Vehicle weight can be reduced with 800V
architecture. Increasing the voltage
allows a lower current to be used, whichallows thinner cables and smaller
electronic components to be used.
This reduces weight and somemanufacturing costs. Lower current also
reduces energy lost to heat, thusincreasing efficiency.
• Higher voltage batteries can provide
greater power to the electric drive motor
and achieve better regenerative braking
at a lighter vehicle weight than 400V
architectures. This also contributes togreater vehicle efficiency.
• 800V architectures are more expensive
to manufacture than their 400V
counterparts due to the smaller market
share and nascence of the technology.
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Where Next?
US - Ratio of Number of Vehicles to

EU - Ratio of Number of Vehicles toCompatible Chargers

Compatible Chargers

454040353530302525202010105502022 Q2 2022 Q3 2022 Q4 2023 Q1 2023 Q2 2023 Q32022 Q2 2022 Q3 2022 Q4 2023 Q1 2023 Q2 2023 Q3

Ratio of 800V Vehicles to 800V Chargers

Ratio of 800V Vehicles to 800V Chargers

Ratio of <800V Vehicles to <800V Chargers

Ratio of <800V Vehicles to <800V Chargers

Chargers
USAEU

2022 Q2

USA2022 Q32022 Q42023 Q12023 Q22023 Q3

800V

1,006

1,524

1,682

1,694

2,008

1,770

<800V

28,672

87,467

102,492

128,481

124,566

123,598

800V

3,149

5,445

7,720

8,679

12,85519,856<800V

167,592

423,871447,799

501,819576,034

635,7292023 Q22023 Q3

Cumulative EV Sales

EU02022 Q22022 Q3

The ratio of 800V vehicles sold tothe number of 800V chargers in the USand EU was compared. The number ofvehicles is a running total of vehicles
sold from January 2019 to the quarterspecified. This was compared to thenumber of available charging stations
for that quarter.
• 800V vehicles will see more success with
consumers in the EU before the US. Thisis because public charging is more
frequently used in the EU than in the US,
making faster charging times morecritical for EU customers.

1515Key takeaway2022 Q42023 Q1800V

34,89142,86549,91959,06974,51097,122<800V

1,275,246

1,476,348

1,717,196

1,963,602

2,236,061

2,538,102

800V

204,948

229,832

268,060

293,054

318,112

346,891<800V

2,867,882

3,215,931

3,786,133

4,232,952

4,759,227

5,316,312• The EC has set minimum charging speed
requirements. Current laws require
stations along major highways to have 1or more 150kW chargers. Charging
operators are frequently including 800Vtechnology in their chargers to futureproof their assets.
• In the US, there are issues (inoperable ornot operating at full capacity) withexisting charging infrastructure that need
to be addressed before 800V stations arebuilt. These fixes can be made, and newstations installed through the NEVIFormula, which provides funding tostates to support further charging station
expansion.
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What to watch out for?
Key takeaway
OEMModele-Tron GT Quattro
RS e-Tron GT
ATTO 3 (Yuan Plus)
Dolphin
SealSong
GV60
GV70
G80 (Electrified)
Hummer EV Pickup
Hummer EV SUVIONIQ 5IONIQ 6EV9Taycan
G9Regions

At the time of writing this report, there
are sixteen 800V models on the market.
These models are spread across 8 OEMs.
These OEMs are gaining earlyexperience with 800V architecture andwill hold a key advantage going forward.
• Porsche only offer one model in 800V
architecture; however, they were thefirst OEM to implement this technology ina production vehicle. The Volkswagen
group have since rolled out thetechnology to Audi. The Volkswagen
Group will likely continue to develop andrefine this technology, starting byexpanding within these two brands
before bringing it to its volume brands.
• Hyundai Motor Group has implemented
800V technology across all its vehicle
brands.
• BYD and Xpeng plan to bring 800Vvehicles to the EU. This will have a large
impact on the industry. Chinese OEMs
can manufacture 800V components
much cheaper. This will allow them tobring vehicles with faster charging times
to market more quickly than WesternOEMs.
• GM first introduced 800V architecturewith the GMC Hummer EV. The electric
Cadillac Escalade will be 800V as well.
5How should you react?

123Prepare

If not already doing so, automakers
who are producing EVs should plan
to include 800V vehicles within their
future line-up.

Implement

OEMs should first implement 800V
architectures in their high-endmodels. This technology should thentrickle down to entry level vehicles
over time.

Refine800V architectures will become lessexpensive with scale. In themeantime, consider offering 800V as
an option on high volume vehicles toallow for cost transparency with theconsumer.

Authors

Michael Graf

Robert Fisher

Research Analyst

Domain Principal

Related SBD Report
Ref: 219
EV BatteryTechnologiesandEcosystem

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ElectricVehicle
GuideRelated SBD Consultancy EV Battery Technology andForecasting EV Infotainment Evaluations
 EV Range Testing

Interested in finding out more?

Most of our work is focused on helping clients go deeper into newchallenges and opportunities through custom projects. If you would like todiscuss recent projects that we have completed relating to EVs andCharging Infrastructure, please contact us.
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