2 Structural & Mechanical Module Design

Enclosure design ensures module protection and integrity. Engineers choose materials like aluminum or plastics for strength, weight, and thermal needs, define IP ratings, plan insulation, handling, mounting, and sealing. CAD and FEA tools are used to simulate and refine the design before prototyping.

Cell retention design ensures safety and durability by securing cells against shock, vibration, and expansion during cycling. For pouch and prismatic cells, maintaining compressive force is key. Designs also consider spacing, insulation, and apply DfM and DfA to enable efficient production and assembly.

Tolerance analysis ensures all module parts fit together properly during assembly. Engineers use CAD tools for stack-up analysis, define critical dimensions, and apply GD&T to communicate limits. Close collaboration with manufacturing helps align design with production capabilities and variability.

DFMEA is a proactive step to identify and reduce mechanical design risks. Engineers evaluate potential failure modes—like fractures or seal issues—their causes and effects, then prioritize risks based on severity, likelihood, and detectability, guiding design improvements and validation efforts.

To ensure safety during events like thermal runaway, modules must include pressure relief features such as rupture discs or vents. These are designed to release excess pressure safely, with defined activation points and flow rates, often guided by pressure codes and CFD analysis.

Mechanical design must meet industry standards for vibration, shock, crush, drops, sealing, and material safety (e.g., REACH, RoHS). Engineers review IEC, ISO, SAE, UN, and regional standards, and conduct required tests to ensure the module is safe, compliant, and market-ready.