Porsche Avoided 120 Prototypes By Using AI to Virtually Test Its Electric SUV | Carscoops

      Virtual simulations enabled Porsche to forgo constructing numerous physical prototypes and significantly reduced the development timeline for the Cayenne EV.

      10 hours ago

      by Chris Chilton

      Porsche harnessed digital technology to conduct virtual testing of its new Cayenne Electric.

      This innovation removed the necessity to create about 120 conventional early prototypes.

      The Cayenne Electric is set to launch later this year and is based on the Macan Electric.

      The application of simulations is not a novel concept in the automotive sector. Manufacturers frequently utilize them to expedite testing and incorporate additional trials that they cannot afford (in terms of time or cost) to perform with actual vehicles. However, for the upcoming Cayenne Electric, Porsche leveraged computational power to bypass a whole step in the traditional vehicle development process.

      “This project was the first where we transitioned directly from digital whole-vehicle testing to pre-series production,” states Dr. Michael Steiner, Porsche's deputy chairman and a key figure in their R&D team.

      Transforming Pixels into Prototypes

      Rather than progressing from design to construction and then to pre-production prototypes, Porsche entirely eliminated the construction phase. They noted that their engineers were conducting digital test drives of virtual prototypes during the design stage.

      Porsche has not disclosed the financial savings incurred by this digital-centric approach, but it must be substantial. The company claims that the virtual testing initiative avoided the construction of around 120 physical test vehicles, which are both costly and time-intensive to manufacture. Consequently, development time was reduced by 20 percent.

      These virtual test drives encompassed laps around the Nurburgring as well as everyday traffic scenarios to replicate real-world conditions. Since components such as tires, dampers, and bushes can be adjusted in the computer system, determining the optimal specifications is relatively straightforward. Each of the virtual components that receive approval is then validated through real-world testing.

      Testing Without Drivers

      Not all simulations necessitate a human driver; many are conducted autonomously by computers. Porsche has created a new test bench to evaluate the motors, battery management, and charging systems under realistic conditions.

      “The machines are so advanced that we can even simulate different asphalt surfaces or tire slip,” explains engineer Marcus Junige, who emphasizes that a key objective was ensuring the Cayenne's powertrain delivers maximum power when requested, which requires excellent thermal management.

      Human Involvement Still Necessary

      Evidently, Porsche’s AI initiative does not completely eliminate the need for physical testing, which began at the pre-series prototype stage. A fleet of SUVs was driven in extreme conditions ranging from the sweltering 122-degree (50 C) heat of Death Valley to the frigid -31-degree (-35 C) climates of Scandinavia, with each vehicle logging approximately 93,000 miles (150,000 km).

      Other Western automakers are likely to adopt similar digital strategies to accelerate their development processes, if they have not done so already. One of the significant threats posed by Chinese manufacturers is not just their competitive pricing, but their speed in bringing vehicles to market, and AI technology will be crucial in helping other countries keep up.

      The Hardware

      The Cayenne Electric is set to make its debut this winter, with sales expected to commence in early 2026. It is built on an extended version of the 800-volt PPE platform utilized in the Macan Electric, featuring a 108 kWh battery that offers a range of 373 miles (600 km) per the WLTP standards, along with Porsche's Active ride suspension. It emits V8-like sounds in track mode and is anticipated to be available in three variants: 394 hp (400 PS / 294 kW) for the base model, 592 hp (600 PS / 441 kW) in the S trim, and 794 hp (805 PS / 592 kW) as a Turbo.