Element Energy Advances Safe and Sustainable Battery Solutions with Simulation

Founded in 2019, Element Energy saw an opportunity to address the pressing demand for more sustainable battery systems. The California-based startup focuses on “improving the safety, intelligence, and economics of large-format battery systems and supporting a circular economy for batteries.” One of its core strategies involves second-life battery (SLB) applications—taking used batteries, especially those retired from EVs, and repurposing them for extended energy storage.

“Creating sustainable battery solutions is our primary goal and mission statement,” says Corrado Cammi, vice president of Engineering at Element Energy. “One of our main focuses is to use our technology in SLB applications. We can take used batteries, for example, from retired EV applications, integrate our hardware/software solution, and redeploy them as energy storage for at least another 10 years. We can do this in an effective way thanks to our architecture and its benefits — throughput management, lifetime extension, and improved safety.”

When refurbished batteries are placed back into service, they can offer up to 40% of the total cost savings over a battery’s extended lifetime, according to the company. Element Energy’s approach keeps older cells out of landfills and back on the grid in applications like backup power systems for private energy providers.

Traditional battery packs are often wired in series, all managed by a centralized battery management system (BMS). This can create inefficiencies because each cell is charged or discharged at the same rate, even if certain cells are more degraded than others. Element Energy’s solution is different. Element Energy places a high priority on battery safety, starting with their distributed battery management system (BMS) architecture.  They distribute BMS control to individual modules, each with its own power conversion stage. Instead of controlling all cells through a single, centralized unit, they allow each module to be monitored and adjusted independently. This localized oversight helps detect and respond to potential issues—like overheating or cell degradation—before they escalate.

Element Energy leverages Ansys simulation software to conduct rigorous structural, thermal, and reliability analyses and support the design of battery modules and BESS containers. By integrating advanced hardware design with real-time diagnostics and Element Energy’s proprietary continuous cloud-based monitoring, the system minimizes malfunctions and prolongs battery life. Element Energy’s master controller aggregates data and sends it to the cloud for ongoing diagnostics, allowing operators to make informed decisions that maximize throughput, preserve battery health, and maintain safety—all without disrupting normal operations.

For Element Energy, advanced engineering simulation isn’t just a productivity boost—it’s essential to their entire mission to deliver safer, more efficient large-format batteries. Early design stages demand a holistic understanding of everything from thermal management to structural integrity. That’s where the Ansys Startup Program and KETIV come in, enabling Element Energy to integrate their proprietary multiphysics simulation at every development step. This deep reliance on virtual testing lets the team iterate rapidly, cut costs, and ensure their batteries meet rigorous safety and reliability standards—outcomes impossible to achieve without simulation at the core.