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 vehicle or airframe.
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, wire lists 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
Vehicle and airframe interface
Making the pack fit the platform it has to live in. Interface control, mass and centre-of-gravity budgets, thermal and cooling interfaces, and the routing constraints that come from the structure around it.
- Interface control definition
- Mass and CG budgets
- Thermal and cooling interfaces
- Installation and removal 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 tools, alongside the engineering
We are building the tooling we already use in-house into products our clients can run themselves. The same discipline applied to battery programme data: part numbering, bills of material and harness definition, handled properly rather than in a spreadsheet that one person understands.
BOM and part number management
Structured numbering and bills of material built for multi-level pack assemblies and revision control.
Harness and EDS data
Wire lists, connector schedules and harness definitions generated from the design rather than retyped.
Design release workflow
Change control and traceability that keeps a programme auditable as it moves.
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 changing them is cheap. 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