Automakers and battery manufacturers are racing to develop battery technology to power the next generation of vehicles and a greener future. The battery in question needs to reinforce the body structure and extend the driving range. Engineers refer to it as a structural battery that holds the promise of lighter weight and greater efficiency. The latest structural batteries are being developed by startups and legacy automakers alike, including the EV pioneer Tesla Inc (NASDAQ:TSLA), General Motors Co (NYSE:GM), battery makers such as China's BYD Co Ltd and CATL.

Geely Automobile Limited's (OTC:GELYF) Volvo Cars in late June revealed a new structural battery design it is developing with Swedish battery maker Northvolt that Volvo said should deliver 600 miles or more of travel between charges. To compare, Tesla Inc's (NASDAQ:TSLA) Model Y can deliver 326 miles.

GM's approach revolves around the Ultium battery that begins with the basic building blocks,  thin pouch-type battery cells, which are bundled into modules, then assembled into large packs. Ultium battery packs will be installed in the upcoming electric Hummer's chassis, stiffening its body, improving the quality of the ride and handling as it reduces vibration and harshness. At least this is how Josh Tavel, GM's executive chief engineer for battery-electric trucks, advertises it.

China's BYD and CATL have developed advanced batteries whose cells are assembled directly into large packs, eliminating the middle step. Both use lithium iron phosphate which is less expensive and less prone to fire hazards, while being friendlier to the environment compared to commonly used cobalt and nickel. However, LFP cells do not store as much energy compared to their nickel cobalt manganese or nickel cobalt aluminum counterparts. Due to a lower driving range they provide, a vehicle needs a larger and therefore, heavier, pack of lithium iron batteries to match the output provided by cobalt and nickel-based batteries.

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