Automotive
EV Battery Pack Thermal Redesign
CFD-driven thermal redesign of a 90 kWh EV battery pack, cutting peak cell temperature by 11°C.
Client: Tier-1 EV Manufacturer
Challenge
Peak cell temperatures during fast charge exceeded warranty thresholds, blocking a launch window.
Solution
A coupled CFD-FEA program identified flow maldistribution and drove a rapid cold-plate redesign.
Engineering Process
How we delivered.
Step 01
Baseline CFD correlation with test data
Step 02
Cold plate topology optimization
Step 03
FEA structural revalidation
Step 04
Pilot build handover
Tools Used
ANSYS FluentANSYS MechanicalSolidWorks
Results
-11°C
Peak cell temp
-18%
Pressure drop
Neutral
Cost impact
Gallery
Project imagery.
Let's build together
Engineering that ships. On time. On budget.
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