Case Study: Advanced Thermal Cell Barrier for EV Battery Packs
A concept-to-manufacture solution for a major automotive OEM to delay thermal propagation in EV batt…
Case Study: Nearshoring a Thermal Cell Barrier Supply to Europe
Redesign and Manufacture of a Battery Component to lower unit costs and exceed performance targets
"We worked very closely with this customer throughout the project, to help them realise their goal of nearshore thermal cell barrier supply to Europe. Our technical team improved the original design and reduced the BOM, while beating the original supplier's price and ensuring full compatibility with the customer’s assembly line.
Navigating all of those improvements to deliver a part that surpassed the performance requirements and testing was a fantastic result. Overall, the customer was delighted with our components and support as an engineering and manufacturing partner."
Kevin Porter, Technical Director
Nearshoring a Thermal Cell Barrier
1. The Challenge
A global battery manufacturer approached us to nearshore the production of an existing thermal cell barrier, moving supply from the Far East to Europe.
The original component worked, but the customer felt the design was inelegant, and several design iterations had left it with features that added complexity without clear justification.
The customer was open to design improvements however, to be successful our component had to meet strict criteria:
- Performance: Achieve a list of required component performance metrics and specifications.
- Compatibility: Maintain full compatibility with the customer’s existing assembly line.
- Financial: Ensure a complete supply chain switch at a commercially viable cost.
- Design: Improve the component’s inelegant design.
Redesign, Enhancement & Testing
2. The Solution
We started by analysing the existing product to understand its functionality. We combined these insights with the customer’s performance brief, and then explored new material options and alternative component designs.
Component Redesign
We developed a streamlined replacement component that reduced the Bill of Materials (BOM) and lowered total manufacturing costs. This included sourcing an advanced insulation material that allowed us to simplify the build in two key ways:
- Inherent Compression Resistance: We utilised the structural properties of the new insulation material to handle the require mechanical compression, which eliminated a redundant part.
- Simplified Profile: The new design naturally prevented debris accumulation, making additional sealing strips obsolete.
Testing Results and Unit Price
We produced prototype parts for customer lab testing and assembly line compatibility trials. The new component successfully passed all testing criteria, a major milestone given the reduced BOM and lower unit cost.
Performance was not only maintained, in key areas it also improved. For example, dielectric performance surpassed requirements by 15%, all while achieving a lower unit price than the original Far East supplier.
Enabling Cost-Neutral Nearshoring
3. The Outcomes
Our redesigned advanced thermal cell barrier surpassed all the strict criteria for the project:
- Performance: Surpassed performance metrics, excelling in key areas such as dielectric strength (+15%).
- Compatibility: Achieved 100% compatibility with the customer’s existing assembly line.
- Financial: Delivered a lower unit price than the original supplier, helping the wider project achieve cost parity.
- Design: Created a sleek, simplified component using multi-functional materials that significantly reduced the BOM.
The customer was delighted with our redesigned component and proposed cost savings. And the project opened up new potential European nearshoring opportunities with the customer.
Results of the Project:
Why did the customer choose Tecman?
Faced with the commercial and logistical challenges of a far-flung supply chain and an overly complex component design, the customer sought out our engineering and manufacturing expertise. They needed a partner who could nearshore production to Europe without increasing costs, compromising quality, or disrupting their supply continuity.
Impressed by our proactive, analytical approach to truly understand their requirements and the existing component, sourcing advanced materials, and improving the design to surpass performance targets while beating the original unit price, won the trust of the customer.
Discuss your project with Tecman
We can support our customers through every stage, from material selection and design phases to choosing the right manufacturing processes. This ensures the delivery of an optimised, cost-effective component designed to effectively overcome challenges and deliver tangible benefits.
Whether you are looking to nearshore component supply to Europe, optimise existing designs, lower your Bill of Materials, or overcome a different challenge, our engineering team is ready to help.
industry-leading engineered components
Delivering tangible value where it matters most
Learn more
Case Study: Precise PET Die-Cuts for Automated Assembly Success
We supported on a critical battery pack component project involving the high-speed automated applica…
Case Study: Die-Cut Protection Film Prevents Transport Damage
We developed a custom die-cut protection film component that eliminated damage during transportation…
Case Study: Added Value Adhesive Gasket for Automotive Interior
Design & manufacture of a custom die-cut adhesive gasket to bond a plastic component to a vehicl…
E-mobility Thermal & electrical Management Solutions
Within the ever-evolving and dynamic e-mobility sector, Tecman is a trusted and proven partner to un…
Advanced Thermal runaway barriers
Effective thermal runaway barriers are essential for optimising cell performance, longevity, and saf…
Adhesive Tape Solutions
We manufacture custom die-cut adhesive tape and engineered adhesive tape solutions
Thermal Management Applications
Advanced thermal management solutions using high-performance materials