Developing a high-performance electric vehicle requires more than simply selecting an off-the-shelf battery pack. The manufacturer needed both standard and extended-range pack options that could be tailored to its unique platform requirements. This meant creating designs that maximized available space within the vehicle’s form factor while delivering the energy density and power necessary to meet ambitious performance and range targets.
In addition to the physical constraints, the packs had to integrate seamlessly with the vehicle’s electrical and thermal systems, ensuring safe operation under demanding real-world conditions. The solution also needed to satisfy a wide range of requirements, from crash safety and vibration resistance to thermal runaway protection and regulatory compliance.
Finally, the packs could not remain conceptual, they had to pass full validation testing prior to launch, proving they could deliver consistent performance, reliability, and safety in both laboratory and field environments. Meeting all of these requirements simultaneously posed a complex engineering challenge that demanded expertise across mechanical, electrical, thermal, and software domains.
Re:Build approached the project as a complete end-to-end development effort, bringing together mechanical, electrical, thermal, and software engineering expertise under one roof. The goal was not only to design battery packs that met performance requirements but also to ensure they could be validated, manufactured, and scaled for future production.
Key elements of the approach included:
By coordinating these disciplines from the start, the team minimized development risks, streamlined validation, and set the stage for a scalable production pathway.
Re:Build delivered a complete, production-ready battery system designed to meet the demanding requirements of modern electric vehicles. The packs were engineered to balance performance, safety, and manufacturability, with a focus on scalability for future builds.
The solution included:
By combining mechanical, electrical, thermal, and software expertise under one roof, Re:Build ensured the packs were not only high-performing but also aligned with the customer’s long-term production and platform goals.
The project delivered battery packs that not only met the technical requirements but also positioned the customer for long-term success. By combining advanced engineering with thorough validation, Re:Build ensured the packs were safe, reliable, and seamlessly integrated into the EV platform. The outcome set a clear path for scaling production and accelerating future vehicle programs.
Let’s discuss how we can bring innovative solutions to your most challenging projects. Contact Re:Build Battery Solutions to learn more about our expertise in Battery Pack Design and Development for advanced applications.
