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Case Study: Nearshoring Supply of a Thermal Cell Barrier to Europe
Redesign and Manufacture of a Battery Safety Component to lower unit cost and surpass performance targets
"We worked very closely with this customer to help them reach their goal of nearshoring 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 and delivering a part that surpassed the performance requirements was a fantastic result. Overall, the customer was delighted with our component and our 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.
Component Redesign & Testing
2. The Solution
We started by analysing and characterising 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.
2.1 Component Redesign
We developed a streamlined replacement component that reduced the Bill of Materials (BOM) and lowered total manufacturing costs. This included switching to an advanced insulation material that allowed us to simplify the component in two key ways:
- Compression Resistance: We utilised the inherent structural properties of the new insulation material to handle the required mechanical compression, which eliminated the need for a frame.
- Simplified Profile: The new design naturally prevented debris accumulation, removing the need for sealing strips.
2.2 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 achievement given the reduced BOM and lower unit cost.
Performance was not only maintained, in key areas it was improved upon. 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 and high-volume production. We ensure the delivery of an optimised, cost-effective component designed to effectively overcome your application challenges and deliver tangible benefits.
Whether you are looking to nearshore component supply to Europe, optimise existing parts, lower your Bill of Materials, or overcome a different application challenge, our engineering team is ready to collaborate with you to develop a bespoke component solution.
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