Cell Selection
The early battery module design phase begins with selecting the right cell format (pouch, prismatic, cylindrical) and chemistry (NMC, LFP, NCA) based on performance, cost, and availability. Next, the series-parallel configuration is defined, shaping voltage, capacity, size, and system complexity.
Mechanical Design
This design phase defines the battery module’s mechanical structure—ensuring cell protection, structural integrity, and ease of assembly. Key outputs include the enclosure design, cell retention, BoM, and detailed manufacturing and assembly documentation.
BMS, Busbar & Electrical Design
This stage designs the module’s electrical architecture—cell interconnects, connectors, CSC integration, and LV harnesses—to ensure safe current flow, accurate monitoring, and reliable external connections, while meeting electrical safety standards for creepage and clearance.
Thermal Management
This stage focuses on thermal management to keep cells within safe operating temperatures, ensuring performance, safety, and longevity. It includes selecting TR-resistant materials, planning cell venting, designing cooling/heating systems, and optimizing thermal interfaces.
Safety & Validation Testing
This stage tests prototype and pre-production modules to confirm performance, reliability, and safety. Validation ensures design meets requirements; safety testing exposes modules to abuse to confirm safe behavior. Both physical tests and simulations are used to predict real-world performance.