Battery pack integration for automotive and aerospace programmes
We design the electrical distribution and mechanical integration that turns a set of cells into an installed, buildable, documented pack.
Everything between the cells and the platform
Integration is where battery programmes lose time. We work on the interfaces — electrical, mechanical, documentary — that sit between a module supplier and a finished, installed product.
Electrical distribution systems
High and low voltage distribution inside the pack: busbar routing, module interconnects, harness architecture, connector and terminal selection, sensing and BMS wiring. Delivered as releasable drawings and bills of material.
- Busbar and interconnect design
- Harness architecture and routing
- Connector and terminal selection
- Sensing, BMS and service loops
Mechanical integration
The pack as an installed assembly rather than a standalone box. Enclosure and module packaging, mounting and load paths, sealing and ingress protection, tolerance stack-up, and the clearances that keep assembly and service realistic.
- Enclosure and module packaging
- Mounting, load paths and isolation
- Sealing and ingress protection
- Tolerance stack-up and clearance studies
Design release and documentation
The output a programme can actually build from. Part numbering and BOM structure, drawing packs, change control, and the traceability that audits and certification reviews ask for.
- Part numbering and BOM structure
- Drawing and data packs
- Engineering change control
- Design traceability and records
Software for the engineering flow, in any industry
We are turning the tools we built for our own engineering work into a product any engineering team can run. One register for part numbers, the bills of material built from them, and the work that takes a design to a build: who owns each part, what has been ordered, what is in stock, what is late. It is not tied to a sector or a product: if you design, buy and build assemblies, it fits.
Part number register
One number for life per part. Revisions side by side, nothing ever deleted.
Multi-level bills of material
Shared assemblies, make / buy / phantom, quantity roll-ups, indented and flat views.
Design to build tracking
Design, procurement and build status on every BOM line; late parts flagged automatically.
Project dashboards
Status worked out from dates, not typed in. Portfolio view and demand combined across projects.
Tasks and pick lists
Work with an owner and a due date, closed with evidence. Pick lists for stores.
Full audit trail
Who changed what, when, with the old and new value.
Where we work
The engineering is the same discipline; the constraints that drive it are not.
Automotive
Passenger, commercial and off-highway electrification. Packaging density, vibration and crash load paths, serviceability, and the cost and cycle-time pressure of a production programme.
Aerospace
Airborne and ground support energy storage. Mass discipline, qualification evidence, material and process control, and documentation written from the start to survive a certification review.
Industrial and marine
Stationary, rail, marine and heavy equipment installations, where duty cycle, environmental sealing and long service life drive the architecture more than packaging does.
How the work runs
Define the interface
Before any geometry, we establish what the pack must connect to — structure, cooling, high voltage, control — and write it down as a controlled interface definition. Most integration failures trace back to this step being skipped.
Architect before detailing
Distribution topology, module arrangement and load paths are settled at concept level, where a change costs hours, not months. Detail design starts once the architecture survives review.
Design for the build
Assembly sequence, tool access, torque reach and service removal are treated as design inputs. A pack that cannot be assembled economically is not a finished design.
Release with traceability
Drawings, bills of material and change history are structured so the programme can build, audit and revise without reverse-engineering the intent.
Ways to work with us
Programme support
Embedded with your engineering team for a defined phase, working to your systems and release process.
Work package
A scoped deliverable — an EDS architecture, an enclosure design, a release-ready drawing pack — priced and delivered as a package.
Design review
An independent assessment of an existing pack design against integration, manufacturability and documentation criteria.
Tell us what you are integrating
Send the platform, the pack concept and the stage you are at. You will get a considered reply from an engineer, not a brochure.
- Replies within two working days
- Happy to work under NDA before any detail is shared
- No mailing list, no follow-up sequence