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

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.

As part of the project, researchers at the BFH’s Centre for Energy Storage investigated the extent to which second-life batteries are suitable for further operation. They also looked into the impact of fast charging on the battery of the electric truck. The project is supported by the Swiss Federal Office of Energy (SFOE).

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.