As the demand for high-performance battery systems grows, engineers face a critical challenge: how to design battery packs that are safer, more compact, and more efficient while maintaining mechanical integrity under extreme conditions. The BATSS project is tackling this head-on, developing mechanical innovations that rethink how battery systems are built.
From modules to a cell-to-pack revolution
Traditional battery packs rely on module-based designs, where individual cells are grouped into modules before being assembled into a full pack. While this approach provides structural stability, it comes with drawbacks: additional materials, complex assembly, and limitations in thermal management.
BATSS is embracing the cell-to-pack approach, which eliminates the need for intermediate modules. This means fewer structural components, increased energy density, and a more streamlined manufacturing process. With fewer materials and interfaces between cells, the system becomes not only lighter but also thermally more efficient—an essential factor in preventing overheating and improving battery lifespan.
However, this shift requires overcoming major mechanical challenges. Ensuring structural integrity while reducing components means redesigning the way cells are housed, supported, and protected. That’s where BATSS partners step in, each contributing expertise in materials, structural engineering, and safety measures.
Building a battery that withstands the unexpected
One of the biggest concerns in battery system design is safety under extreme conditions—from mechanical shocks and vibrations to potential fire hazards. BATSS engineers are developing advanced fire suppression strategies that integrate fire-resistant materials and innovative thermal barriers directly into the battery structure.
A key player in this effort is the FLEXcooler®, a technology that has already demonstrated its ability to slow thermal propagation—a major cause of battery fires. The team is also testing a range of coatings, encapsulation techniques, and fire-retardant materials to ensure that, even in worst-case scenarios, battery failures can be contained and managed safely.
Another feature is the use of structural health monitoring (SHM) based on ultrasonic sensing, which can detect early signs of mechanical stress, such as cell deformation and swelling. SHM can significantly reduce the risk of catastrophic failures.
Pushing the limits with advanced simulations
To validate these innovations, BATSS is conducting rigorous mechanical simulations that replicate real-world conditions, from crash tests to extreme vibration scenarios. These simulations are crucial for ensuring that the newly designed battery packs can withstand operational stresses while meeting industry standards.
By using cutting-edge computational tools, engineers can refine the design before physical prototypes are built, optimising everything from shock absorption and housing materials to vibration resistance and impact durability. The result? A battery system that is not only more efficient but also engineered for real-world resilience.
The future of battery design is here
With these mechanical innovations, BATSS is redefining battery system architecture, making it safer, more efficient, and ready for the demands of modern electrification. The transition to a cell-to-pack approach, combined with next-generation fire safety mechanisms and real-time monitoring, marks a significant leap forward in battery engineering.
As the project continues to push the boundaries of design and testing, one thing is clear: the batteries of the future won’t just be more powerful; they’ll be smarter, safer, and built to last.
