Modular Battery Pack Architecture

R&D By Engineering Design Lab

Conceptual Design, Prototyping, Design For Injection Molding, DFM

 

EDL engineered a modular, waterproof battery pack that delivers exceptional thermal performance and manufacturability. The design features outer-facing aluminum panels in direct contact with the cells, enabling efficient heat dissipation while maintaining a slim profile. The enclosure balances multiple constraints—cooling, waterproofing, assembly, and injection moldability—through precision-molded plastic frames that interlock with minimal tolerance stack-up. Screw locations are strategically placed outside the sealing zone to preserve the integrity of the waterproof barrier while allowing robust mechanical fastening.

 

The layout accommodates tooling constraints and screw access paths, ensuring ease of assembly and repeatability in volume production. EDL’s iterative design process optimized the pack for manufacturability, leveraging DFM (Design For Manufacturing) principles and real-world validation to deliver a rugged, scalable solution tailored for demanding environments.

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Client Testimonial:

I highly recommend Tomek and the team he assembled at his Engineering Design Lab for any design challenge but particularly those tasks that require skills at the intersection of traditional engineering disciplines. Tomek genuinely loves his craft as an engineering designer, and that enables him to come up with creative solutions, backed by analysis. Additionally, with his detail-oriented side - he sees his designs through from prototyping, to EVT, DVT, PVT and all the way to mass production. Tomek quickly acclimatized himself with our team and its dynamic, and the nuances of the project. He worked in a flexible manner, integrated well with existing team and provided top notch engineering services on a day by day basis.

Dmitri Stepanov, MASC, P.Eng
Product Manager
Kai Concepts LLC