Novelis Develops World’s First Aluminum Sheet Battery Enclosure

To meet the EV market’s growing needs, Novelis has worked with industry partners to develop the world’s first aluminum sheet battery enclosure. Available globally, it is built with Novelis Advanz™ aluminum products and is up to 50 percent lighter with a low$/kg premium compared to an equivalent steel design at substantially lower weight. When compared to aluminum extrusion and casting-intense designs, it is the most cost-effective solution for mass production vehicles. The enclosure accommodates all battery cell types and is designed particularly for battery electric vehicles with larger power packs such as pick-up trucks, sport utility vehicles and crossovers.

Utilizing highly-formable alloys, the battery enclosure gives automakers the ability to achieve deep drawn, complex shapes tailored to meet requirements of specific vehicle designs and joining processes.

The lightweight, high-strength material can help extend range, allowing vehicles to travel six-to-10 percent further on a single charge. Acknowledging safety as its top priority, Novelis conducted extensive simulations and analysis of the enclosure, confirming its ability to protect batteries from road debris and vehicle crashes.

With our investment in design, joining and crash management capabilities, we were able to create a stronger, more efficient, and cost-effective enclosure that can be fully customized to meet our customers’ needs.

The battery enclosure was developed in Novelis’ recently launched Customer Solution Centers, which brings research and technical platforms, operations and commercial development together to increase collaboration and innovation between the company and its industry partners.

It is the center’s first project and sets a stage for the conception and development of new aluminum solutions that will drive the future of design and innovation across many industries.