This study presents a detailed review and comparative analysis of current and emerging battery pack architectures for electric heavy-duty vehicles, emphasizing modularity, energy efficiency, and space optimization. Initially, various types of electric vehicle battery chemistries are reviewed, with a particular focus on those currently utilized in commercial applications.

The analysis highlights the significance of understanding trends in future battery technologies on energy density and anticipated performance improvements.The current Volvo electric truck architecture and various components is presented for better understanding. Many commercial manufacturers existing battery layouts are reviewed to understand the technological trends and their offering. This gives an overall knowledge of battery architecture. A new battery pack layout is proposed and evaluated against two baseline configurations. Layout 1 demonstrates a less product cost and potential improvement in space utilization over Layout 2, whereas Layout 2 offers advantages in modularity, vehicle integration flexibility, ease of maintenance, and reduced pack size.

The proposed design addresses critical engineering considerations such as weight-to-energy ratios, thermal management, structural safety, and manufacturability.

Quantitative assessments indicate a 60–65% increase in range potential over conventional layouts, along with improved single-charge usability and reduced component complexity. The implications for commercial vehicle manufacturers, including integration with E-Axle architecture and alignment with industrial leaders such as Volvo Trucks, are also discussed.

The paper concludes with a technical evaluation of battery pack mass, cell count, volumetric efficiency, and range calculations to inform future design strategies.