Porsche’s Innovative Testing Approach
Porsche applied digital technologies for the virtual testing of the new electric Cayenne Electric model. This avoided the need to build approximately 120 traditional early prototypes. The debut of the Cayenne Electric is scheduled for the end of this year, and it is based on the Macan Electric platform.
Simulations in the Automotive Industry
The use of simulations is not new in the automotive industry. Manufacturers regularly use them to accelerate testing and conduct additional trials that are impossible to perform with real cars due to time and cost constraints. However, with the future Cayenne Electric, Porsche used computing power to skip an entire stage in the traditional car development program.
This project was the first in which we moved directly from digital testing of a whole vehicle to pre-series production, says Dr. Michael Steiner, Deputy Chairman of the Executive Board of Porsche and a key figure in the research and development team.
From Pixels to Prototypes
Instead of transitioning from the design phase to the engineering phase and then to pre-series prototypes, Porsche managed to completely skip the engineering phase. The company’s engineers sent virtual prototypes on digital test drives already at the design stage.
Porsche does not name the exact amount of savings from this digital strategy, but it is undoubtedly significant. The virtual testing program avoided the construction of about 120 real test vehicles, which are not only expensive but also require a lot of time to produce. As a result, the development time was reduced by 20%.
Virtual Test Drives
Virtual test drives included laps on the Nürburgring, as well as simulations of everyday road situations to model real-world usage. Since components such as tires, shock absorbers, and bushings can be modified in the computer program, it is relatively quick and easy to determine which specification works best. Each of the approved virtual components is then tested in the real world for confirmation.
Testing Without Drivers
Not all simulations require a human behind the wheel in the Gran Turismo style. Many of them are run by computers only. Porsche developed a completely new test bench for engines, battery management systems, and charging under realistic conditions.
The machines are so sophisticated that we can even reproduce different asphalt surfaces or tire slip, says engineer Markus Jünige, noting that one of the clear goals was to ensure the Cayenne’s powertrain delivers full power every time the driver demands it, which requires serious thermal management.
The Human Factor is Still Needed
Porsche’s AI experiment, naturally, does not completely eliminate the need for physical testing, which fully began at the pre-series prototype stage. The fleet of SUVs still underwent trials in various conditions: from the scorching heat of Death Valley with temperatures of 50°C to the freezing cold of Scandinavia at -35°C, with each car covering about 150,000 km.
Technical Specifications
The Cayenne Electric debuts this winter and is expected to go on sale in early 2026. Built on a stretched version of the 800-volt PPE platform used in the Macan Electric, it is equipped with a 108 kWh battery providing a WLTP range of 600 km, and the Porsche Active Ride active suspension. In track mode, it produces V8-like noises, and it is reportedly available in three power variants: 400 hp for the base Cayenne, 600 hp for the S version, and 805 hp for the Turbo.
Other Western automakers will undoubtedly use the same digital techniques to accelerate their developments if they aren’t already. One of the main threats from Chinese manufacturers lies not only in their aggressive pricing but also in how much faster they bring cars to market, and artificial intelligence technologies will be key to helping other countries keep pace.
This approach not only demonstrates technological progress but also indicates a paradigm shift in the automotive industry, where digital tools are becoming an integral part of the development process. The efficiency and speed provided by such methods could prove decisive in the competitive battle on the global market, especially considering the growing presence of Chinese brands.