Lightweight composite battery box
for innovative electric vehicle
Lightweight composite battery box for innovative electric vehicle
D2H Advanced Technologies was tasked with designing a new battery box for an American EV manufacturer developing their latest electric vehicle, with strict targets for both weight and rigidity.
The result drew on our extensive knowledge of lightweight composite materials, as well as our experience with battery packs and cooling requirements, to deliver a solution that surpassed all key targets.
The result was a new composite battery box that retained the required form factor, was stiffer and highly tolerant of vibrations, yet weighed significantly less than the original component. In fact, although the client had set a target of 110kg, we were able to deliver a completed assembly that weighed just 88kg, achieving a saving of more than 60kg over the original component.
By working closely with the client’s preferred manufacturing partner, we were able to ensure the final design met cost requirements as well as the performance needs, with additional assistance provided with tooling design.
““Weight can be a crucial factor in EV design, with every extra kilogram incurring a cost in terms of reduced overall range. Asking for a 40kg weight saving on a battery box measuring 2 x 1.2 metres is a tall order for anyone, but when D2H responded with a composite design that didn’t so much beat our target as obliterate it, we knew we’d made the right decision to commission them.”
– Craig McCarthy
President, Aerodine Composites