Virtual simulations helped eliminate the need for dozens of physical prototypes thus slashing development time for the Cayenne electric.
17 Sep 2025 | 1800 Views | By Akbar Merchant
The all-new Porsche Cayenne Electric will be officially revealed in the coming months, but ahead of its global debut, Porsche has detailed the SUV’s unique development process, one that leans heavily on digital simulations to an unprecedented degree.
While computer simulations have long been part of automotive R&D, Porsche ...
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The all-new Porsche Cayenne Electric will be officially revealed in the coming months, but ahead of its global debut, Porsche has detailed the SUV’s unique development process, one that leans heavily on digital simulations to an unprecedented degree.
While computer simulations have long been part of automotive R&D, Porsche has taken the practice further than ever before with the Cayenne EV. The company says it moved directly from digital whole-vehicle testing to pre-series production, skipping the traditional construction-phase prototypes altogether.
“This project was the first in which we moved directly from digital whole-vehicle testing to pre-series production,” explained Dr. Michael Steiner, Porsche’s deputy chairman and head of R&D. The strategy eliminated the need for around 120 physical prototypes and cut development time by 20 percent.
New Cayenne tested virtually on the Nürburgring
Using powerful simulations, Porsche engineers were able to run virtual Cayennes around the Nürburgring, as well as through everyday driving environments, to test everything from suspension setups to tire specifications. Components such as dampers, bushes, and tires were digitally optimized before being validated in real-world conditions.
Not all tests required a driver at all, Porsche developed a new test bench that put the electric SUV’s motors, battery management, and charging systems through rigorous virtual trials, even simulating different asphalt surfaces and tire slip. One focus, according to engineer Marcus Junige, was ensuring that the Cayenne EV always delivers full power on demand, requiring advanced thermal management solutions.
Despite the digital-first approach, Porsche stresses that physical testing remained essential. Pre-series prototypes of the Porsche Cayenne electric were subjected to extreme climates, from the 122°F (50°C) heat of Death Valley to the -31°F (-35°C) cold of Scandinavia, each prototype logging roughly 150,000 km (93,000 miles) of real-world driving.
Powertrain and Launch Timeline
Built on a stretched version of the 800-volt PPE platform shared with the Macan Electric, the Upcoming Porsche Cayenne EV will house a 108 kWh battery offering up to 600 km WLTP range. The SUV will also come with Porsche Active Ride suspension; there will also be V8-inspired sound effects in track mode.
A choice of three power outputs with the entry-level “Base model” getting a 394hp setup, the mid-level Cayenne S electric delivering 592hp and the high performance Cayenne Turbo electric good for 794hp.
The production-spec Porsche Cayenne Electric will debut this in the coming months, with global sales set to begin in early 2026.