Service

AES delivers superior solutions, services, and strategies through our systematic approach that has earned us the profound trust of leading global companies.

We bring together high-performing, highly collaborative teams that work across disciplines to explore strategies, tinker  with technology and provide optimized solutions and quality services to our clients

Battery Design & Development Capabilities

  • Requirements & Compliance Definition (use case, UL/IEC, targets)
  • Cell Selection & Validation (chemistry, supplier, screening tests)
  • System Architecture (S/P config, voltage, energy, rack/container layout)
  • Electrical Design (busbars, fuses, contactors, pre-charge, wiring)
  • Thermal Design (air/liquid cooling, CFD, temperature uniformity)
  • Mechanical Design (module/pack enclosure, IP rating, structural safety)
  • Structural Simulation  (Lifting, Vibration, Shock, Crush, Drop, and Thermal)
  • BMS Development (SOC/SOH, balancing, protections, comms)
  • Safety & Protection Strategy (fault detection, venting, TR mitigation)
  • Prototype Builds: EVT → DVT → PVT (engineering → validation → pilot)
  • Testing & Certification (performance, abuse, UN38.3, UL9540/9540A)
  • Manufacturing Readiness (DFMA, PFMEA, tooling, EOL testing)
  • SOP & Field Support (ramp-up, monitoring, feedback loop)

Structural & Thermal Analysis- Capabilities

Structural Finite Element Analysis (FEA):

Global Structural Integrity:

  • Static structural analysis of the entire battery enclosure   under vehicle loading conditions
  • Validate mounting interface strength for frame and chassis attachment.
  • Simulate stack load, ensuring the base plate can support the full   battery module weight

Crash & Impact Simulation:

  • Analyse frontal, side, and bottom impact scenarios (as per UN   38.3, AIS-048, etc.)
  • Simulate thermal runaway protection structures under crash conditions.
  • Drop test simulations for pack handling and shipping safety

 

Structural Finite Element Analysis (FEA)

Vibration and shock Analysis

  • Modal and harmonic analysis of the enclosure to identify natural frequencies
  • Random vibration simulations for road load durability
  • Fatigue life of mounting brackets and fasteners under cyclic loads
  • Vibration-induced damage to internal components (e.g., connectors, busbars)
  • MIL-STD-810H – Environmental vibration, shock, and mechanical loads

Local Component Validation

  • Base plate stiffness and deformation under mechanical and thermal loads
  • Cell tray deformation due to battery weight and expansion forces
  • Cover warpage under bolt load, sealing pressure, or external impact
  • Reinforcement and rib design effectiveness in high-stress zones

Structural Finite Element Analysis (FEA):

Material & Topology Optimization

  • Perform material efficiency studies to reduce weight while meeting strength targets
  • Topology optimization to refine structural layouts and reduce unnecessary mass
  • Optimize rib patterns, wall thickness, and support locations for manufacturability and stiffness

Regulatory & Safety Compliance

  • Simulate loading scenarios to comply with global safety norms (UNECE R100, UL 2580, IEC   60068-2-6, IEC 60068-2-27, IEC 60068-2-64, etc.).
  • Test correlation and design validation reports

Multiphysics & Coupled Analysis:

Thermo-Structural Coupled Analysis

  • Thermal expansion-induced stresses in the base plate, casing, and lids
  • Validate bolt preload variation and sealing performance under temperature cycles.
  • Fatigue life degradation analysis from mechanical and thermal cycling, Electro-Thermal Analysis
  • Model heat generation from battery cells based on current flow and internal resistance.
  • Evaluate temperature rise and dissipation across cell trays, barriers, and casings.
  • Assess thermal runaway propagation risk under internal short circuit or cell failure.

Multiphysics & Coupled Analysis:

CFD-Thermal Coupling

  • Simulate air or liquid cooling flow over and within the enclosure
  • Coolant channel efficiency in the base plate or around modules
  • Study hot spot formation and optimize airflow for uniform temperature distribution
  • Ventilation behaviour under normal and failure conditions
  •  Solve for thermal and pressure gradients to guide cooling design and vent placement

 

 

 

AES looks forward to providing your organization with our full range of design development services.  Contact us for a free consultation or quote. Our team is here to assist you with all your design development needs.

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