Technologies
How we engineer lightweight, safety-critical enclosures for the high-voltage battery packs at the heart of every EV.
Electric vehicle battery enclosures are among the most demanding structures in modern mobility. They must protect high-voltage cells from crash intrusion, seal against water and dust to IP67 or better, dissipate thermal loads from the pack, provide structural stiffness to the vehicle, and do all of this at the lowest possible mass so that vehicle range is preserved.
Our approach combines high-pressure die-cast aluminum trays, extruded and roll-formed frame members, and stamped or die-cast covers into a single validated system. Structural casting and mega-casting let us consolidate dozens of stamped and welded parts into one node — reducing weight, joint count and warranty risk.
Material choice is a trade-off between mass, stiffness, thermal conductivity and cost. Aluminum alloys dominate today's premium EVs for their strength-to-weight ratio; high-strength steel remains competitive in cost-sensitive platforms; multi-material hybrid designs are emerging where local reinforcements protect the crash cell.
Joining is where enclosures live or die. We combine self-piercing rivets, flow-drill screws, structural adhesives, friction-stir and laser welding — chosen station by station for the specific joint's load path, sealing requirement and serviceability.
Every enclosure we ship is validated against global crash, side-pole, drop and immersion standards, with in-house metrology, helium leak testing and dielectric testing built into the line. From CAD through PPAP, our engineering, tooling and program-launch teams own the enclosure as a full sub-system — not just a set of parts.