ZF opens 800V test lab to advance electric vehicle innovation

ZF has opened a pioneering 800V Test & Validation Laboratory at its R&D Hub near Solihull, aiming to accelerate the development of next-generation electric vehicles (EVs). The facility is the first of its kind for ZF in the UK and one of only a few nationwide. Partially funded by the Advanced Propulsion Centre (APC), the lab is designed to support the rollout of advanced 800V systems, which promise significant gains in efficiency, charging speed, and vehicle performance.

The laboratory, which is 46 square metres in size, will enable ZF to carry out crucial high-voltage (HV) testing for its own projects and for third-party clients in the automotive sector. The facility is also accredited to work with tier-one suppliers and original equipment manufacturers (OEMs), ensuring that a broader range of next-generation mobility projects can benefit from the shift to 800V architecture.

Adrian Mitcham, Head of Special Applications at ZF, explained that the market has been seeking a dedicated site for this level of testing: “OEMs want the compelling benefits of 800V, but finding facilities capable of validating these higher-rated systems has not been easy. Our goal is to provide this much-needed testing capacity, not just for ZF, but for the wider mobility sector.”

Currently, most electric vehicles are built using 400V systems, which typically require 20 minutes of charging to add 200 kilometres of range. In contrast, 800V systems could cut that time in half. They also offer additional benefits, such as lighter wiring, which could reduce overall vehicle weight. When paired with Silicon Carbide MOSFETs, these systems could deliver up to 10% efficiency gains, potentially reducing battery size or increasing vehicle range.

ZF’s new test lab will initially focus on commercial vehicle applications. Among the first projects to utilise the facility was the validation of a new fuel cell air compressor for trucks and buses, carried out by ZF’s Commercial Vehicle Solutions (CVS) division. More recently, the lab was used to validate a fuel cell Hydrogen Recirculation Blower, which ZF unveiled at the IAA Transportation 2024 event.

The laboratory was designed with flexibility and safety in mind. Its modular inverter architecture supports both 400V and 800V systems, and safety features include an interlocked, monitored door and active discharge resistance to minimise the risk of hazardous energy build-up. The facility has also been future-proofed, with infrastructure capable of handling up to 1,500V DC at 45kW, with the potential to increase this to 90kW.

ZF’s new site will also support the training of engineers, partnering with the Institution of Mechanical Engineers (IMechE) to offer HV training programmes. The company plans to use the facility to train future engineers to work safely on 800V systems, further cementing its role in the advancement of electric mobility.

In addition to its commercial applications, the lab will be made available for academic projects, supporting innovation and research in the UK’s electric vehicle sector.