E-Truck charges for the first time with more than 1.1 megawatts of power

Technical breakthrough in practical test in SFOE demonstration project

Winterthur (CH), 26/08/2025 – In July 2025, Designwerk Technologies AG achieved a charging power of over one megawatt for electric HGVs under real conditions – a milestone in the demonstration project supported by the Swiss Federal Office of Energy (SFOE). This means that the rapid charging of large HGV batteries is becoming a reality, overcoming a key hurdle for successful long-distance operation. Until now, the typical market charging power was around 350 kW.

The tests took place in July at the depot of Nationalstrassen Gebiet VI, known as GEVI, in Oberbüren SG, Switzerland. These new results demonstrate that the Megawatt Charging System (MCS) provides a crucial foundation for the nationwide deployment of long-haul electric HGVs in Switzerland. This means the main objective of the project has been achieved.

Charging tests with peak values

Preliminary internal test series had already been conducted in order to best coordinate charging communication, control units and power electronics. In final tests, the charging power was gradually increased until a peak value of 1,140 kilowatts was achieved. This is eight percent more than the original target of 1,050 kilowatts.

During a complete charging cycle of a Designwerk prototype HGV with a battery capacity of 1,000 kilowatt-hours, charging from 10 to 80 percent state of charge took 42 minutes. 625 kilowatt-hours of energy were transferred, with an average charging power of 906 kilowatts – the highest continuous power on the market. This allows an electric 40-tonne HGV to cover a distance of 500 kilometres.

The required charging times fall within the statutory driver break periods, which makes the day-to-day operation of electric long-haul HGVs significantly easier. For comparison: around 81 kilowatt-hours were charged in the first five minutes alone – enough to fully charge an electric car.

Flexible energy storage with battery buffers

Designwerk’s megawatt charging system is designed as a container solution and can temporarily store surplus energy in integrated battery buffers. This means that locally generated solar power can be used even when there is no direct sunlight. In addition, the electricity grid is relieved of peak loads and the need to expand grid connections is eliminated. Alongside new storage units, second-life batteries from decommissioned electric HGVs can also be used, offering both ecological and economic advantages.

Expertise in special vehicle construction as a success factor

Designwerk not only develops charging infrastructure, but also electric special-purpose vehicles. This combination enables optimum coordination between chargers and vehicles. “Thanks to mega charging, a 40-tonne HGV can now charge as quickly as an electric car – only with significantly more power. This is the key to electrifying heavy-duty transport,” explains Niels Ross, Project Manager for Charging Technology at Designwerk.

A milestone for the industry and decarbonisation

The test results open up new perspectives for the use of electric HGVs in long-haul transport. Daily ranges of up to 1,000 kilometres are technically feasible, even for vehicles with high energy demands. For charging point operators, Designwerk’s battery-supported technology offers a way to provide megawatt charging infrastructure without the need for grid expansion.

The use of electric HGVs in long-haul transport would save thousands of tonnes of CO₂ annually – a crucial step towards the decarbonisation of heavy goods transport. The advantages of electric HGVs are also reflected in registration figures. The number of battery-electric HGVs registered in Switzerland rose by 41.2 percent in the first two quarters of 2025 compared to the previous year.

In the coming months, Designwerk aims to advance the integration of intelligent control functions and grid integration. Meanwhile, small-scale series production is underway, and the final MCS communication protocol is being implemented.

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Infobox

Test period and location
When: 28 – 31 July 2025
Where: Nationalstrassen Gebiet VI (GEVI), Oberbüren SG

Test setup	Vehicle: Designwerk prototype e-truck, 800 Volt platform, total capacity of 1,000 kWh (divided into 4 x 250 kWh lithium-ion batteries)
	Charging infrastructure: Megawatt Charging System (MCS) with integrated battery buffer (lithium-ion NMC)
Measured values	Maximum charging power: 1,140 kW (8% above target value)
	Continuous load test: 625 kWh in 42 minutes (10–80% SoC)
	Average charging power: 906 kW
	Maximum charging current: 1,530 A
Project objectives and results	Objective: Demonstration of megawatt charging under real conditions
	Result: Technical objective achieved, charging times correspond to statutory driver break periods
Special features	Use of integrated buffer storage for off-grid charging
	Possible use of second-life batteries
	Container-based, fully mobile all-in-one solution
Project participants	Project Management: Designwerk Technologies AG
	Support: Swiss Federal Office of Energy (SFOE)
	Pilot Customers: Galliker Transport AG, Nationalstrassen Gebiet VI (GEVI)
	Project Partners: Bern University of Applied Sciences (BFH), Eastern Switzerland University of Applied Sciences (OST), Wyssmann LLC

About Designwerk

Designwerk Technologies AG specialises in electromobility for commercial vehicles, with a particular focus on developing, driving, charging and storing. Our founders’ passion for electromobility grew during the 80-day, all-electric world record circumnavigation with the specially developed Zerotracer fully-enclosed electric motorcycle.

Since its founding in 2008, Designwerk has driven electromobility forward with innovative products and projects with the aim of promoting sustainable mobility. Small-series electric trucks, mobile fast chargers, battery-backed megawatt fast charging stations and modular high-voltage battery systems are developed and manufactured under the Designwerk brand. The electric HGVs include the first fully electric refuse collection vehicles on Swiss roads as well as electric HGVs with what are currently the largest battery capacities and ranges on the market. The chargers are widely used by European vehicle manufacturers. The modular traction batteries enable small and medium-sized vehicle manufacturers to make the successful transition to electro-mobility.

The Volvo Group has held a stake in Designwerk since 2021. Today, the company employs 190 staff at three sites in Winterthur (CH) and one site in Lottstetten (DE).

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