These days, no one blinks an eye at two-day, one-day, and even same-day package deliveries. Despite the plethora of localized fulfillment and distribution centers that have cropped up to meet the demand, delivery trucks still need to make considerably long drives, often over highways. To reduce fuel and maintenance costs as well as carbon emissions, companies are investing in electric trucks for their delivery fleets. While turning to electric trucks is a promising solution, the battery packs incorporated into these automotive designs often fall short in the lifetime needed to make long-distance highway travel feasible.

To help overcome the issue of battery lifetime, a consortium of universities and industry partners incorporated multiscale simulation and a custom simulation app into the battery manufacturing process. The organizations involved in this project were Aurobay, Resolvent, the European Commission, the Technical University of Denmark (DTU), Vinnova (the Swedish Agency for Innovation Systems), Innovation Fund Denmark, and Volvo Group Trucks Operations.

The simulation app, built by Resolvent, a Denmark-based engineering consultancy that specializes in green energy, enables the R&D department at Volvo to easily test battery lifetime performance.

The Multiscale Simulation of Laser Welding for Optimal Battery Pack Manufacturing project — referred to as “LaserBATMAN” — was initiated in May 2022 and wrapped up in May 2025 (Ref. 1). Although BATMAN here refers to battery manufacturing and not the famous masked superhero, the goals for the project also strove for greatness.

The LaserBATMAN project aimed to optimize two key performance metrics for battery packs: robustness and lifetime (Ref.

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