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.

You can watch this session along with all sessions from the Automotive Tech Forum 2026 virtual event on demand by visiting https://www.automotiveforum.eetimes.com/

Related Content

• How Semiconductors Will Drive EV Growth
• Exploring On-Board EV Systems from 400 V to 800 V
• New design frontiers in BMS hardware and software
• Shifting the EV Bus to 800 V: Benefits and Design Challenges
• GaN enables efficient, cost-effective 800V EV traction inverters

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