EV design: The truth about 400-V to 800-V battery transition
In electric vehicle (EV) designs, the shift from 400-V to 800-V battery systems is now a pressing issue. So, the panel discussion on the first day of Automotive Tech Forum 2026 was a good venue for a reality check on the future of 800-V EV architectures.
The panel titled “Powering the Electric Vehicle: From Semiconductors to Systems” explored the latest in battery management system (BMS) designs and what battery modeling tells us about the design challenges as we move toward 800-V systems. And how design building blocks like motor control in EV traction are coping with this transition.
The panelists discussed how 800-V EV architectures could reshape vehicle power distribution. Jerry Shi, sector general manager for EV, HEV, and Powertrain at Texas Instruments, spoke about the emerging 800-V EV design landscape, specifically from a drivetrain standpoint. He also outlined critical design challenges and viable solutions in this design arena.
Carsten Himmele, marketing manager for Automotive at Allegro MicroSystems, cautioned about the industry-wide adoption of 800-V battery systems. “The 400-V battery systems will still dominate mainstream markets due to cost and complexity trade-offs.”
Rohan Samsi, VP of GaN Business Division at Renesas, echoed similar sentiments while envisioning a deeper adoption of 800-V architectures to address range anxiety and efficiency concerns. He acknowledged the challenges such as cost, complexity, and consumer preferences. “The trade-offs between 400-V and 800-V architectures relate to component complexity and service warranty costs.”
So, in the 400-V to 800-V transition, there was a consensus that 800-V systems offer advantages in fast charging and reduced weight. However, for now, panelists expect that 400-V systems will remain dominant in mainstream markets due to their affordability.
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- Shifting the EV Bus to 800 V: Benefits and Design Challenges
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