Donut Lab Unveils Technical Specifications for Verge TS Pro Solid-State Battery as Production Begins

Donut Lab, a Finnish technology startup specializing in energy storage solutions, has released comprehensive technical details regarding the solid-state battery pack currently powering the Verge TS Pro Gen2 electric motorcycle. This announcement comes as the company continues to position itself as a pioneer in the transition from traditional lithium-ion chemistries to solid-state technology, which is widely regarded as the "holy grail" of electric vehicle (EV) propulsion. In a detailed technical briefing led by Ville Piippo, Donut Lab’s co-founder and Chief Technology Officer, the company provided a deeper look into the architecture, thermal management, and charging performance of the battery system, which it claims is the first of its kind to reach production readiness for the consumer market.

The integration of this technology into the Verge TS Pro Gen2 marks a significant milestone for both the battery manufacturer and the motorcycle industry. Verge and Donut Lab assert that this collaboration has produced not only the world’s first solid-state-powered electric motorcycle but also the fastest-charging two-wheeler currently available. Despite the ambitious nature of these claims, the release of specific internal configurations and cooling strategies provides the most transparent look yet at a technology that has remained shrouded in controversy and industry skepticism.

Architectural Design and Cell Configuration

The core of the Verge TS Pro Gen2’s energy storage system lies in Donut Lab’s proprietary 94 watt-hour (Wh) cells. In the "Standard Range" iteration of the motorcycle, the battery pack is comprised of 192 individual cells. These are organized in a 2P 96S configuration—meaning two cells are connected in parallel to form a pair, and 96 of these pairs are connected in series. This specific arrangement results in a nominal capacity of approximately 18 kilowatt-hours (kWh), with a maximum capacity reaching 20 kWh.

For riders requiring greater endurance, Donut Lab has also developed a "Long Range" version of the battery pack. This higher-capacity variant offers a nominal capacity of roughly 30 kWh. Notably, the engineering team managed to maintain the same physical footprint for the enclosure across both versions, suggesting a high level of modularity and energy density optimization within the casing. The 96-series configuration allows the system to operate at a maximum voltage of 400V, aligning it with the high-voltage architectures typically found in modern passenger EVs rather than the lower-voltage systems common in many light electric vehicles.

The internal physical layout consists of four distinct modules layered atop one another. These modules are slightly offset to facilitate structural integrity and thermal efficiency. Between each layer of cells, Donut Lab has installed heat transfer plates. These plates serve as the primary conduit for moving thermal energy away from the cell surfaces toward the exterior of the pack, where the cooling system can dissipate it.

Thermal Management and the Challenge of Air Cooling

One of the most striking revelations in the technical breakdown is the battery pack’s reliance on air cooling. In the high-performance EV sector, liquid cooling is generally considered the gold standard for managing the intense heat generated during rapid DC fast charging and high-speed discharge. However, the compact dimensions of a motorcycle frame present unique packaging challenges that often preclude the use of complex liquid pumps and radiators.

To address this, Donut Lab utilizes a heat sink and a small fan assembly on each side of the battery pack. Piippo likened the appearance of these fans to those found on high-end PC processors. This active air-cooling system draws heat from the internal transfer plates and exhausts it into the ambient air. While Piippo described the design as "very compact" and efficient for the motorcycle’s form factor, the reliance on air cooling appears to be a limiting factor in the battery’s peak performance.

Previously, Donut Lab had suggested that its cells were capable of handling charging speeds of up to 200 kW. In the Verge TS Pro Gen2, however, the peak charging power is capped at approximately 100 kW. The company clarified that this reduction is a direct consequence of the motorcycle’s thermal limitations. Without the heat dissipation capacity of a liquid-cooled system, the pack cannot sustain the 200 kW input without risking thermal degradation. Nevertheless, the company maintains that in a larger vehicle—such as a passenger car with sufficient space for liquid cooling—the same 94 Wh cells could achieve a 0-80% charge in as little as five minutes.

Charging Performance and C-Rate Analysis

Despite the thermal constraints, the Verge TS Pro Gen2 demonstrates charging metrics that significantly outpace the current industry standard for electric motorcycles. Using a DC fast charger, the bike can replenish its battery from 10% to 80% in approximately 11 minutes. A more comprehensive top-up from 10% to 90% is achieved in just under 15 minutes.

From a technical standpoint, the "C-rate" of this charging cycle is particularly impressive. The C-rate is a measure of the rate at which a battery is charged or discharged relative to its maximum capacity. With a 20 kWh maximum capacity and a peak input of 103 kW, the Verge TS Pro Gen2 operates at a C-rate of slightly over 5C. To put this in perspective, most modern electric car batteries operate at C-rates between 1C and 3C, with only the most advanced systems approaching 4C. A 5C rate indicates that the battery is being charged at five times its total capacity per hour, a feat that typically requires highly stable chemistry and efficient thermal control.

For the end-user, these numbers translate to high utility. Donut Lab estimates that the motorcycle can add approximately 12 miles of range for every minute it is connected to a fast charger. With an estimated total range of 217 miles, a five-minute "splash and dash" stop could provide an additional 60 miles of travel, effectively eliminating the range anxiety often associated with electric touring.

Industry Context and Scientific Skepticism

The claims made by Donut Lab have not been without pushback from the scientific and engineering communities. Solid-state batteries differ from traditional lithium-ion batteries by replacing the liquid or gel electrolyte with a solid material, such as a ceramic, polymer, or sulfide-based substance. This transition promises higher energy density, improved safety (due to non-flammability), and faster charging.

However, Donut Lab has yet to release a detailed chemical breakdown of its cells or provide public access to its patent filings. This lack of transparency has led some experts to question the legitimacy of the "solid-state" label. The company’s claims are undeniably bold: an energy density of 400 Wh/kg (compared to roughly 260-300 Wh/kg for top-tier lithium-ion cells), a lifespan of 100,000 charge cycles, and a construction that requires no rare-earth materials.

In the battery industry, a cycle life of 100,000 is virtually unheard of; most automotive-grade batteries are rated for 1,000 to 3,000 cycles before significant capacity loss occurs. Furthermore, the claim of "zero rare-earth materials" suggests a departure from common nickel-manganese-cobalt (NMC) or even lithium-iron-phosphate (LFP) chemistries, though the company has not specified what materials have been used in their stead. While independent tests have confirmed the fast-charging capabilities of the cells, the long-term durability and the exact nature of the solid electrolyte remain points of contention.

Chronology of Development and Production Status

The journey of Donut Lab from a Finnish startup to a potential disruptor in the EV space has moved at a rapid pace.

• Initial Reveal: Donut Lab first gained international attention by claiming to have cracked the code for production-ready solid-state cells, focusing on high power-to-weight ratios suitable for performance vehicles.
• Testing Phase: Over the past year, the company has released a series of videos and data sets showing individual cell tests, including high-current discharge and rapid charging demonstrations.
• Verge Partnership: The collaboration with Verge Motorcycles was announced as the primary vehicle for bringing this technology to market, utilizing Verge’s innovative hubless motor design alongside the new battery tech.
• Production Launch: According to company reports, production of the Verge TS Pro Gen2 with the solid-state battery pack officially commenced last month.

As of this writing, the industry is still waiting for the first units to reach the hands of independent reviewers and third-party testing laboratories. These evaluations will be critical in verifying whether the battery maintains its performance in real-world conditions and whether it truly exhibits the characteristics of a solid-state system.

Broader Implications for the EV Market

If Donut Lab’s technology performs as advertised, the implications for the broader EV market are profound. The ability to charge a vehicle in under 15 minutes would remove one of the primary barriers to EV adoption. Furthermore, the potential removal of rare-earth materials from the battery supply chain would significantly reduce the environmental and ethical concerns associated with mining cobalt and nickel.

The success of the Verge TS Pro Gen2 could serve as a proof-of-concept for larger automotive manufacturers. Companies like Toyota, Volkswagen (via QuantumScape), and Nissan have all invested billions into solid-state research, with most projecting mass production only by the late 2020s. A small startup successfully beating these giants to market would represent a major shift in the technological landscape.

However, the road ahead remains challenging. Scaling production from low-volume motorcycles to high-volume passenger cars requires overcoming massive manufacturing hurdles and ensuring long-term reliability. For now, the Verge TS Pro Gen2 stands as a high-performance experiment—a glimpse into a potential future where the limitations of battery technology are no longer a constraint on the open road. As the first units roll off the production line, the eyes of the automotive world remain fixed on Finland to see if Donut Lab can turn its wild claims into a tangible reality.