Investors are watching closely as next-gen battery innovations disrupt the electric vehicle landscape. A new modelling study reveals how Ilika’s solid state battery (SSB) technology could dramatically reduce EV pack weight, simplify design, lower costs, and cut fast-charging times — all while enhancing performance and safety.
Solid state batteries are emerging as a transformative upgrade to lithium-ion technology, offering superior safety, lighter weight, and greater efficiency. Balance Batteries Ltd, a UK-based battery specialist, has undertaken a modelling exercise to explore the full potential of Ilika’s SSB technology in a real-world electric vehicle application. Using the popular Hyundai Ioniq 5 as a baseline, the study demonstrates how Ilika’s innovation could deliver substantial improvements across multiple dimensions of battery pack design and performance.
The Hyundai Ioniq 5’s current battery pack delivers 84.1 kWh of usable energy and weighs in at 482 kg. The existing system utilises 384 SK On lithium-ion cells arranged in a standard modular architecture, complete with thermal management components such as cold plates and structural modules. This setup, while efficient by today’s standards, still carries the burdens of added weight, complex cooling, and fire mitigation measures required to ensure safety.
To estimate the potential impact of Ilika’s solid state cells, Balance Batteries used the SK On ABD0013 cell as a reference point, thanks to its similar format and chemistry. While the reference cell delivers 293 Wh/kg, Ilika is targeting 350 Wh/kg for its first product — a substantial leap. Modelling showed that by substituting Ilika’s cells into the same pack configuration, the pack weight could be reduced by 46.8 kg at the cell level alone.
Beyond individual cell improvements, the modelling explored broader system-level advantages. Thanks to Ilika’s high safety profile — derived from its oxide-based solid electrolyte and silicon anode — Balance Batteries proposed eliminating several internal structural and thermal protection components. For instance, switching to a simplified solid cell carrier and removing foam separators and module housing saved 26 kg. Additional weight reductions came from the ability to discard certain thermal barrier materials, saving another 6.6 kg.
The cooling system, one of the heaviest parts of current battery packs, could also be streamlined due to the higher thermal tolerance of Ilika’s SSBs. Although a full removal of the cold plate was deemed too aggressive, reducing its complexity remains feasible. Side impact protection beams, each weighing nearly 16 kg, could also be thinned thanks to reduced fire risk, delivering further incremental weight savings.
Fast-charging performance also improves with solid state technology. Because SSBs can tolerate higher internal temperatures during charging, they reduce the time needed to reach operational heat levels. This could cut the 10-80% state of charge time from 18 minutes down to just 12 minutes — a significant advantage in user convenience and charging infrastructure efficiency.
Cost modelling revealed strong financial incentives. Even though a transition to solid state would involve a one-time £78k increase in tooling due to new pack design features, the elimination of certain thermal materials reduced this by £17k. Moreover, the redesign of components delivered £2.5k in variable cost savings per vehicle. At a production scale of 70,000 units per year, these savings could amount to £175 million annually, with the break-even point achieved after just 22 vehicles.
Reduced pack weight also translates into real-world driving benefits. According to WLTP testing simulations, the lighter SSB-equipped vehicle consumed only 180.1 Wh/km, compared to 185.8 Wh/km for the original — a 3% efficiency gain solely from weight savings. The result is better acceleration, reduced tyre wear, and lower overall energy demand.
Ilika’s cells are still in development, and performance figures will need to be validated upon commercial release. Nonetheless, Balance Batteries’ modelling presents a compelling case for the future of solid state batteries in EVs. From energy density gains to cost savings and safety enhancements, the advantages stack up decisively.
Ilika plc (LON:IKA) is a pioneer in solid state battery technology enabling solutions for applications in Industrial IoT, MedTech, Electric Vehicles and Consumer Electronics.
