System-level assessment of dynamic reconfiguration for lifetime and cost outcomes in electric vehicle battery packs

The electrification of transport relies heavily on lithium-ion batteries, yet conventional fixed-configuration battery packs suffer from structural inefficiencies such as cell-to-cell variability and premature failure. Dynamic battery reconfiguration, enabled by intelligent control of switching hardware around individual cells, provides an alternative pack architecture. Here we present a systematic, battery technology-agnostic evaluation of the lifetime and economic benefits of reconfigurable battery packs using a statistically grounded framework based on detailed cell modelling across diverse design and usage conditions. We show that reconfigurable battery packs can extend battery lifetime by over 20%, particularly in high-voltage applications such as electric trucks and long-range passenger vehicles. Despite higher upfront costs, reconfigurable packs can reduce lifetime cost by deferring replacements and retaining greater residual value. A sensitivity analysis identifies robust thresholds for economic viability: battery capacities above approximately 50 kWh, annual driving distances below 12,150 km, and additional upfront costs under 7.16%. These findings position dynamic reconfiguration as a scalable, cost-optimised architecture for next-generation battery platforms, and provide a quantitative foundation for future hardware design, management software, and life-cycle sustainability assessments.