Porsche Skipped 120 Prototypes By Letting AI Test Its Electric SUV Virtually

The use of simulations is nothing new in the car industry. Automakers regularly use them to speed up testing and add extra trials that they can’t afford (in time and/or money) to carry out with real cars. But with the upcoming Cayenne Electric, Porsche used computer power to skip an entire process in the traditional car development program.

“This project was the first in which we moved directly from digital whole-vehicle testing to pre-series production,” says Dr. Michael Steiner, Porsche’s deputy chairman and a big cheese on the R&D team.

From Pixels to Prototypes

Instead of moving from the design to the construction phase and then to pre-production prototypes, Porsche managed to skip the construction phase altogether. It says its engineers were sending virtual prototypes on digital test drives as early as the design phase as a result.

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Porsche hasn’t put a price on how much money this digital-focused strategy saved, but it must be tons. It claims the virtual testing program eliminated the need to build around 120 actual test vehicles, which are not only expensive, but time consuming to produce. As a result, development time was cut by 20 percent.

The virtual test drives included, of course, laps of the Nurburgring, but also took in everyday traffic situations to simulate real world use. Because components like tires, dampers and bushes can be modified in the computer program, it’s relatively quick and simple to work out which spec works best. And each of the approved virtual components is then tested in the real world to provide validation.

Testing Without Drivers

Not all of the simulations require a human to be behind the wheel Gran Turismo-style. Many are run by the computers alone. Porsche developed a brand new test bench to put the motors, battery management and charging systems through their paces under realistic conditions. 

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“The machines are so sophisticated that we can even display different asphalt surfaces or tyre slip,” says engineer Marcus Junige, who says one clear goal was that the Cayenne’s powertrain always deliver full power when the driver calls for it, something that demands seriously good thermal management.

Humans Still Required

Naturally Porsche’s AI experiment doesn’t entirely remove the need for physical testing, which fully kicked in at the pre-series prototype stage. A fleet of SUVs was still driven everywhere from the blazing 122 degree (50 C) heat of Death Valley to the freezing -31-degree (-35 C) expanses of Scandinavia, each vehicle covering around 93,000 miles (150,000 km).

Other Western carmakers are sure to employ the same digital tricks to speed up their development, if they aren’t already. One of the major threats posed by the Chinese isn’t simply their aggressive prices, but how much faster they are at getting cars to market, and AI tech will be crucial in helping other nations keep pace.

The Hardware

The Cayenne Electric debuts this winter, and should go on sale early in 2026. Built around a stretched version of the 800-volt PPE platform used in the Macan Electric, it features a 108 kWh battery for a 373-mile (600 km) WLTP range and Porsche’s Active ride suspension. It emits V8-like noises in track mode and will reportedly come in three tunes: 394 hp (400 PS / 294 kW) for the base Cayenne, 592 hp (600 PS / 441 kW) in S trim and 794 hp (805 PS / 592 kW) as a Turbo.

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