New Energy Vehicle 800-1000V High-Voltage Architecture and Supply Chain Research Report, 2025
Research on 800-1000V Architecture: to be installed in over 7 million vehicles in 2030, marking the arrival of the era of full-domain high voltage and megawatt supercharging.
In 2025, the 800-1000V high-voltage architecture for passenger cars in China is shifting from a “high-end configuration” to a “mainstream standard configuration”. Technological dividends are driving an energy efficiency revolution and the popularization of fast charging. In the short term (2025), the popularization of the 800-1000V high-voltage architecture for passenger cars in China will mainly benefit from the competing needs, supercharging demand, and implementation of supercharging piles of OEMs; in the long term (2030), the popularization of the 800-1000V high-voltage architecture for passenger cars in China will mainly depend on the localization of SiC and the maturity of the full-domain high-voltage ecosystem.
From the supply chain perspective, the 800-1000V high-voltage architecture is currently limited by the insufficient maturity of the component supply chain and high costs. In this report, we divide the technologies of the 800-1000V high-voltage architecture into 6 categories and 15 subcategories, and evaluate the suppliers, maturity, and development trends of each technology segment.
According to statistics from ResearchInChina, there were only 13 passenger car models equipped with 800V high-voltage architecture in China in 2022. In 2024, there were 47 passenger car models with 800V high-voltage architecture on sale in China. As of the first half of 2025, the passenger car models with 800V high-voltage architecture on sale in China have outnumbered 70.
800V technology has been available to battery electric passenger cars priced at RMB100,000-150,000. For example, the full range of Leapmotor B01, with a starting pre-sale price of RMB105,800, is equipped with an 800V high-voltage platform as standard; BYD has launched the world's first mass-produced “full-domain 1000V high-voltage architecture” for passenger cars, which implements 1000V for all high-voltage components such as batteries, motors, power supplies, and air conditioners.
According to statistics from ResearchInChina, the sales of passenger cars with 800V high-voltage architecture in China totaled 840,000 units in 2024, a year-on-year upsurge of 185%, with a penetration rate of 6.9%. It is expected that the penetration rate will reach 9.5% in 2025 and exceed 35% in 2030. With the launch of models with 800V full-domain high-voltage architecture, it is expected that in 2030, new energy models equipped with 800-1000V architecture will exceed 7 million units, over 8 times more than the current scale.
Technology trends of 800-1000V supply chain: OEMs quicken their pace of self-building megawatt fast charging piles.
Currently, the competition among major OEMs in flash charging technology is becoming increasingly fierce, and their technical characteristics and advantages are different. BYD, relying on the vertical integration of batteries, electric drives, energy storage, and charging piles, has shown its obvious advantages in the charging field. Examples include BYD’s megawatt flash charging, Zeekr’s 1.2MW all-liquid-cooled supercharging, Tesla’s V4 supercharging, Voyah’s VP1000 megawatt supercharging, and Huawei’s all-liquid-cooled megawatt-level supercharging.
Zeekr officially launched the first 1.2MW all-liquid-cooled charging pile with the world's highest single-gun peak power, in the second quarter of 2025, and a megawatt ultra-fast charging station equipped with 10 1.2MW liquid-cooled charging piles. The single-gun power of this device directly breaks the global record, 3.4 times that of Tesla's V4 supercharging pile (350kW) and twice that of Porsche's 800V high-voltage fast charging. The first “megawatt charging stations”, each equipped with 10 liquid-cooled piles, have entered the construction stage.
All-liquid cooling technology has become a key to breakthrough. The power limit of traditional air-cooled charging piles is stuck at 600kW. The liquid cooling system compresses the cable diameter by 40% and reduces the weight of the charging gun by 35% through closed-loop coolant circulation, achieving a current transmission efficiency of over 95%. The measured data shows that the Zeekr 009 equipped with this technology can enable a range of 500km with a 10-minute charge when matched with a liquid-cooled pile; according to the test on Zeekr 7X, it can charge 50kWh in 10 minutes and achieve a range of 440km.
A single station with 10 supercharging piles can simultaneously support 20 vehicles (dual-gun configuration) to charge at 1.2MW power, with a total power load of 12MW, equivalent to the peak electricity consumption of a medium-sized shopping mall. This requires the power grid side to be equipped with an energy storage system and an intelligent power distribution module. Zeekr’s engineers confirmed that they have jointly developed a dynamic load management system with the State Grid, intelligently adjusting the actual operating power of the charging station by ±30% with the grid load.
Technology trends of 800-1000V supply chain: 3-5C gradually becomes mainstream, and 10C high-rate batteries come.
The launch of the 800V-1000V high-voltage architecture for passenger cars first aims to solve the problem of supercharging speed. To meet the needs of supercharging, the first component system to be updated in high-voltage architecture passenger cars is the battery system. In 2025, the charging rate of 800V battery systems in battery electric passenger cars on sale is mainly be 3-5C; BYD's 1000V full-domain high-voltage platform is even be equipped with 10C batteries.
The popularization of 800-1000V battery systems in automobiles is mainly thanks to the supercharging demand of new energy passenger cars and the technical support to achieve charging efficiency:
Supercharging demand: The 800V high-voltage architecture supports above 350kW supercharging, and shortens the charging time from 5% to 80% SOC to less than 20 minutes, so as to solve users' “range anxiety”. The charging voltage of the 800V supercharging system is generally between 600V-1200V, and the realization of supercharging power requires the cooperation from the 800V architecture on the vehicle side.
Supporting supercharging piles: At present, China has entered the “supercharging era”. As local governments vigorously promote the construction of supercharging networks, upstream and downstream enterprises in the supercharging industry chain are also actively cooperating to promote the construction of a supercharging ecosystem. At present, supercharging stations still adopt a supercharging piles + fast charging piles combination, with the charging power of supercharging piles up to more than 480kW. Liquid-cooled supercharging stations include Huawei’s all-liquid-cooled supercharging stations, Xpeng’s S4/S5 liquid-cooled supercharging stations, and Li Auto’s 5C supercharging stations/shuttle supercharging stations).
800V high-voltage battery charging rate: With the mass production of a number of batteries with a rate of 4C or higher in 2024, high-rate batteries + 800V supercharging piles will greatly improve the energy replenishment experience for electric vehicles. In 2025, high-end models will develop towards 5-6C, low-to-mid-end models will move towards 3-4C, and plug-in hybrid models will also break through 2C.
The realization of a charging rate of 4C and above requires breakthroughs in battery materials and BMS capable of high-precision control. At present, mainstream power battery packs can support a 2C charging rate. The use of electrolyte additives, isotropic graphite, graphene and other materials can improve the conductivity of battery materials to a certain extent, thereby improving the stability of ternary materials under high voltage.
In the process of new energy vehicles moving from “range competition” to “all-scenario application”, CATL has built a complete passenger car product matrix covering battery electric, hybrid, supercharging, and low-temperature scenarios through three technical routes: Qilin Battery (high density), Shenxing Battery (super fast charging), and Xiaoyao Battery (hybrid system).
CATL has expanded battery competition to multiple dimensions such as low-temperature performance, cycle life, and energy replenishment efficiency through material innovation (e.g., lithium-sodium AB system), structural optimization (CTP 3.0), and algorithm upgrade (AI BMS). The pattern of the hybrid market has been reshaped: the 400km EV mode range and 4C charging rate of Xiaoyao Battery have forced competitors to accelerate technological iteration.
Battery electric track: Qilin Series breaks the energy density ceiling through ternary lithium materials to serve high-performance vehicles; With lithium iron phosphate, Shenxing Series popularizes "long range + super fast charging" to seize the mainstream market.
Hybrid track: Xiaoyao Battery makes up for the “range shortcoming” of hybrid models, and facilitates evolution of plug-in hybrids into “real new energy vehicles” with 400km EV mode range + all-climate performance.
Supercharging ecosystem: Both Shenxing PLUS and Qilin 2.0 are equipped with AI polarization BMS algorithms, and combine with CATL's self-built supercharging network (in cooperation with Huawei/StarCharge) to form a “battery-charging-service” closed loop.
In April 2025, CATL released the second-generation Shenxing Superfast Charging Battery. With a peak charging rate of 12C and a power of 1.3 megawatts, this lithium iron phosphate (LFP) battery can achieve a 520km range with a 5-minute charge. To achieve 12C fast charging, optimizations in materials and cell design are still required. The main focus is on improving the transmission speed of lithium ions and electrons:
In terms of improving lithium ion transmission, ultra-crystalline graphite and SEI regeneration-enhanced electrolyte are used. On the one hand, they accelerate the transmission speed in the SEI layer and graphite; on the other hand, they can repair cracks in fast-charging graphite particles and improve cycle life.
The improvement of electron transmission is relatively conventional. The so-called balanced electron flow seems to be the full tab (generally, half of the winding is connected, and all laminations are full tabs); and the carbon-coated lithium iron phosphate cathode material also already exists.
CALB, based on the One-Stop design and manufacturing concept, has upgraded to a “U-type” cylindrical battery that supports 6C fast charging:
Compared with the tabless structure, the "U-type" design shortens the current path by 70%, reduces the structural internal resistance by 50% and the DC internal resistance by 40%, increases the Z-direction space utilization by 3%, and cuts the number of welding machines in the production line by about 70%.
In addition to lower resistance and higher space utilization brought by structural optimization, combined with chemical material system technology, CALB stated that the U-type cylindrical battery can achieve 6C fast charging with a cell energy density of 300Wh/kg.
Technology trends of 800-1000V supply chain: electric drive system
At the Auto Shanghai 2025, all Tier 1 exhibitors have launched electric drive systems adapted to 800V high-voltage platforms. The high-voltage transformation of electric drive systems has become an industry consensus. The main development trends include the following:
Multi-integrated design of electric drive systems: Functional modules such as motor, reducer, controller, DC/DC, and PDU are highly integrated, with volume reduced by 30% and power density exceeding 5kW/kg (industry average is about 3.5kW/kg).
Large-scale application of wide-bandgap semiconductors: The proportion of SiC (silicon carbide) and GaN (gallium nitride) devices exceeds 60%, the switching frequency is increased to more than 20kHz, and the system loss is reduced by 15%-20%.
New motor technology - axial flux motor: Power density reaches 6kW/kg, suitable for scenarios such as in-wheel motors.
Less-rare-earth permanent magnet motors: Use ferrite or nanocrystalline materials to avoid the risk of rare earth supply, with costs reduced by 20%.
Breakthroughs in motor miniaturization and quietness: The noise of flat-wire oil-cooled motors is less than 70dB.
Under 800V high-power fast charging, the demand for thermal management has upgraded, requiring optimized motor design (for example, Xiaomi SU7 improves NVH through the high-frequency characteristics of SiC): Xiaomi SU7 Ultra is equipped with an 871V high-voltage platform, which adopts a self-developed Q7 motor (with a speed of 21,000rpm) and SiC electronic control, enabling a 220km range with 5-minute charge, and also optimizes the NVH performance through the high-frequency characteristics of SiC modules.
800-1000V electric drive systems use SiC (silicon carbide) power modules to improve efficiency, adopt oil-cooling technology to enhance heat dissipation, and utilize flat wire motors to increase power density. Their modular design supports different voltage platforms, high integration reduces volume and weight, and intelligent control algorithms are employed to enhance performance.
Expanded power range: Magna eDrive covers 50-250kW, meeting the needs of A0-class to SUV models;
Voltage platform upgrade: The actual operating voltage of IM LS6 reaches 875V, nearly 10% higher than the industry's nominal 800V;
Cost control: Further cost reduction is required for SiC modules and low-rare-earth materials (such as Nidec's magnetic steel cooling optimization);
Thermal management limits: Ultra-high-speed motors with 24,000rpm put forward higher requirements for heat dissipation (InfiMotion’s mechanical limit is 28,000rpm).
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