A battery pack for commercial vehicles offering a range of 1,000 kilometres on a full charge and a charging time of 25 minutes: these are the performance figures claimed by China’s Catl for its new Tectrans II commercial vehicle battery platform, unveiled at IAA 2026. Its technology is based on modularity: by configuring a variable number of standard battery packs, Tectrans II can meet different energy capacity and payload requirements, with a claimed range of up to 1,000 kilometres. The system is compatible with both integrated electric axle (e-axle) architectures and central drive systems, and allows operators to switch flexibly between charging and rapid battery swapping.
A key element of the project is the standard interface, which keeps external dimensions, electrical connections and communication protocols unchanged, while allowing cell chemistry and pack design to evolve over time. According to Catl, this means future technology upgrades can be applied both to new commercial vehicle models and those already in production, without requiring major changes to the platform. The company estimates that the modular approach can reduce vehicle development times for manufacturers by up to 50% and cut research and development costs by 60-70%.
In terms of energy performance, the battery achieves a gravimetric energy density of 170 Wh/kg, which Catl says is around 13% above the industry average and translates into an estimated additional payload of 0.6 tonnes for the same installed capacity. In the top configuration, charging to 80% takes 25 minutes, thanks to megawatt charging system (MCS) technology. A full-tab, low-impedance design, described by the company as an industry first, raises the system’s round-trip efficiency to 96%. For use in heavy commercial vehicles, Catl claims a service life of 12 years or 1.5 million kilometres, with 70% residual capacity at the end of the cycle.
The battery pack’s physical strength includes a hot-stamped steel top cover, which the company says can withstand being repeatedly stepped on 10,000 times by a 180-kilogram adult without deformation, and a bottom plate capable of withstanding impacts of up to 1,000 joules. The extruded aluminium enclosure, reinforced with anti-crush ribs, provides lateral resistance of up to 250 kN, while corrosion protection is guaranteed for 15 years, an important requirement for operation in coastal environments or harsh climates. The IPXXB protection rating remains valid even when the main connectors are disconnected, improving safety during maintenance work.
On the electronics side, a battery management system with independent branches isolates any faulty branch while keeping the remaining ones operational. Proprietary insulation fault localisation technology determines whether a fault originates in the battery or in other vehicle components, speeding up diagnosis. Multi-layer cybersecurity, extending from chip hardware to vehicle system software, complies with international information security standards throughout the product development process. Catl says Tectrans II has undergone a validation programme that includes whole-vehicle torsion testing and external fire resistance tests, alongside data gathered from real-world operating experience.
On the sidelines of IAA, Catl signed a memorandum of understanding with DHL Group to develop electrified freight corridors in Europe, building on an earlier agreement between the two companies dating back to September 2024. The agreement combines DHL’s logistics network and operational expertise with Catl’s battery technology and electrification ecosystem. Vehicle manufacturers and other partners are also expected to be involved in developing dedicated electric vehicles and launching pilot projects. “The electrification of commercial vehicles will develop over more than a decade,” said Zhu Lingbo, CTO of Catl’s Global Business Unit, outlining the company’s intention to position itself as a key supplier for the electrification of freight transport worldwide.
P.R.
