IFEVS, in close collaboration with CIDAUT, is developing an innovative battery case concept for vehicles operating in the urban logistics sector. The development builds upon an existing IFEVS design, which is being upgraded to comply with StS requirements and specifications while integrating the advanced materials developed by AMMR. To ensure maximum production agility, the manufacturing strategy relies exclusively on laser cutting, sheet metal bending, and punching techniques. By eliminating the need for moulds and stamping tools, this flexible approach significantly reduces the time required to progress from design to prototype construction, enabling the case to be developed within just a few days.
At the heart of the concept is a multi-layer architecture, consisting of two thin sheets of Advanced High-Strength Steel (AHSS) separated by an intermediate layer of insulation foam. This sandwich configuration has been engineered to provide outstanding resistance against debris impacts, making it highly suitable for a wide range of vehicle architectures and body configurations. In addition to its protective function, preliminary simulation results obtained by CIDAUT indicate that the enclosure delivers excellent thermal insulation, effectively reducing the influence of external temperature variations.
To bring the design to fruition, project partners are developing advanced technical solutions. On the one hand, BWI and AMMR are investigating innovative joining technologies capable of connecting the layers while minimising the use of mechanical fasteners like screws. Concurrently, PRIMA is refining the manufacturing strategy to seamlessly integrate the mentioned processes. While current optimizations are based on CIDAUT’s numerical simulations, the entire concept will be validated through physical testing in the future stages of the project.