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Lightweight, high-strength aluminum solutions for next‑generation EV battery systems

Novelis advances electric mobility with solutions for aluminum-intensive EV battery enclosures, cooling and cell components that improve safety, energy density and sustainability while reducing mass and total system cost.

Applications Overview

  • Battery Enclosures Cell-to-Pack-ready (CTP): Aluminum sheet‑intensive tubs, roll‑formed frames and integrated thermal management bottom plates deliver best‑in‑class mass efficiency and crash protection while enabling deep‑drawn, complex geometries tailored to OEM platforms.
  • Cooling Plates & Thermal Management: Integrated structural cooling plates and laser/roll‑bonded concepts leverage aluminum’s high thermal conductivity to manage heat, improve pack durability and lower mass.
  • Cell & Module Components: Aluminum current‑collector cathode foil for electrodes and precision components for cell housings support performance, manufacturability and recyclability across EV platforms.

Key Benefits

Aluminum enclosures can be up to 50% lighter than equivalent steel enclosures; over 20% mass reduction versus baseline aluminum extrusion concepts.

Best‑in‑class frame mass efficiency below 1.0 kg/kWh; ~30% higher energy density versus benchmark designs.

High‑strength Advanz™ alloys (e.g., s650) in roll‑formed sections enable safety‑critical performance and scalable manufacturing.

CTP‑ready architectures with integrated structural cooling plates and deep‑drawn tubs for packaging efficiency.

Circularity and low carbon: high recycled‑content alloys and closed‑loop partnerships reduce CO₂ footprint.

“This partnership represents a major milestone in roll‑formed aluminum adoption for EV structures. By utilizing advanced roll forming and Novelis’ high‑strength aluminum, we are not only redefining how battery enclosures are designed for both performance and sustainability, but also unlocking new opportunities to apply this technology across a range of structural automotive applications, further advancing lightweighting and efficiency.”

Chief Technology Officer at Shape Corp.

Novelis Advanz®  5F – RC5754
Novelis Advanz® 6CM – s118
Novelis Advanz® 6CM – s300
Novelis Advanz® 6F – e170
Novelis Advanz® 6HF – e200
Novelis Advanz® 6HF – s200
Novelis Advanz® 6HS – e600
Novelis Advanz® 6HS – s600
Novelis Advanz® 6HS – s615
Novelis Advanz® 6HS – s625
Novelis Advanz® 6HS – s650
Novelis Advanz® 7UHS – s701
Novelis Fusion® 6HF – e200
Novelis Fusion® 6HF – s200
Fusion® 6HF – s200RW