Mechanical & Structural Design for Lithium Battery Systems
In custom lithium battery systems, structural design directly impacts safety, durability, environmental resistance, and assembly efficiency—not just whether the battery fits. Standard designs often fail to meet the specific space, strength, and protection requirements of real-world applications.
Since 2002, LARGE delivers integrated mechanical solutions covering dimensional matching, material selection, protection design, and resistance to vibration, shock, and corrosion.Our designs are tailored to your device form factor ,operating environment , and assembly process ensuring stable performance and long service life.
From space-constrained installations and complex geometries to extreme temperatures and outdoor water/dust exposure , we engineer structures that enable
your battery packs to perform reliably in industrial, outdoor, and portable device applications.
Since 2002, LARGE delivers integrated mechanical solutions covering dimensional matching, material selection, protection design, and resistance to vibration, shock, and corrosion.Our designs are tailored to your device form factor ,operating environment , and assembly process ensuring stable performance and long service life.
From space-constrained installations and complex geometries to extreme temperatures and outdoor water/dust exposure , we engineer structures that enable
your battery packs to perform reliably in industrial, outdoor, and portable device applications.
Why Structural Design Matters?
Many device-level issues originate from poor alignment between the cell chemistry, voltage platform, BMS strategy, and thermal management. Common challenges include:
01
Space Constraints
Maximizing energy density within limited device space requires precise dimensional control and optimized internal layout.
02
Complex Geometries
Non-standard shapes and irregular mounting interfaces demand custom structural designs to ensure compatibility and stability.
03
Lightweight & Strength Balance
Advanced material selection and structural engineering minimize weight while maintaining mechanical strength—ideal for portable and mobile equipment.
04
Vibration & Drop Resistance
Cell fixation and reinforcement structures are optimized for vibration and impact conditions to ensure long-term reliability.
05
Water & Dust Protection
Sealing strategies and IP-rated enclosure designs are tailored to operating environments, supporting outdoor and industrial applications.
06
Hextreme Environment Adaptability
High/low temperatures, salt spray, and other harsh conditions impose strict material and structural requirements. We deliver targeted solutions for each scenario.
How We Design Your Custom Lithium
Battery Pack Structure
Our structural design starts with your application requirements. We
integrate installation space, power dissipation, assembly methods, and
certification needs into a unified mechanical solution.
integrate installation space, power dissipation, assembly methods, and
certification needs into a unified mechanical solution.
Protection Level Design (IP Rating)
Protection Level Design (IP Rating)IP ratings from IP54 to IP68, with reinforcement options for
salt spray, mold resistance, and corrosion protection.
salt spray, mold resistance, and corrosion protection.
Dimensional Customization
Millimeter-level precision based on your device’s 3D space, with support for custom interfaces and mounting features.
Weight Optimization
Weight is reduced through material selection and mechanical optimization—without compromising impact resistance or service life.
Enclosure Material Selection
A full range of materials is available—from engineering plastics to aerospace-grade metals (see material cards below).
Structural Layout
Coordinated design of cell arrangement, wiring routes, BMS placement, and thermal paths to reduce assembly time and improve serviceability.
Enclosure Material Selection
From lightweight designs to high-strength structures, from cost efficiency to corrosion resistance, we support a wide range of materials and provide expert material selection guidance.
Carbon Fiber
Ultra-lightweight
High strength
High strength
7075 Aerospace Aluminum
High strength
6063 Aluminum Alloy
Excellent heat dissipation
Cost-effective
Cost-effective
304 Stainless Steel
Corrosion resistant
Durable
Durable
Cold-Rolled Steel Sheet
High impact resistance
PC / ABS + Pcnum
Flame retardant (UL94-V0)
PVC / Engineering Plastics
Cost-efficient option
Specialized Industrial Materials
Acid and alkali resistant
Explosion-proof
Explosion-proof
Protection & Shock-Resistant Design
IP Rating Customization
Customized IP54 / IP65 / IP67 / IP68 sealing solutions
according to device environment, with optional salt spray
and anti-mold features.
Shock & Drop Resistance Highlights
· Cell Fixation: Brackets / Metal Clamping Bars / Metal frame
· Reinforced Ribs & Die-Cast Frame
· Enclosure Anti-Deformation & Stress Dispersion Design
· Dedicated Cushioning Solutions for high-vibration equipment (AGV / tooling)
Prototyping & Strength Verification
We support rapid prototyping and engineering validation to shorten product verification cycles and reduce trial-and-error costs.
CNC Machining
Fast fabrication of metal housings and frames with high precision, ideal for structural verification.
3D Printing
Rapid iteration of plastic parts and mock-ups, enabling early verification of assembly and form.
Prototype Molds
Support limited production and structural strength testing.
An engineering closed loop from concept to mass production, supporting prototype testing and design iteration.
Strength & Reliability Verification
Our laboratory covers key validation items to ensure that structural solutions remain
stable and reliable in mass production and field applications.
stable and reliable in mass production and field applications.
Water & Dust Resistance (IP)
Rain, immersion, and dust tests conducted according to the target IP rating.
Drop & Impact Testing
Multi-directional drops, corner impacts, and energy absorption verification.
Vibration & Fatigue Testing
Simulates transportation and operational vibration environments to evaluate fixation and connection reliability.
Salt Spray & Corrosion
Assess material durability and anti-corrosion measures under marine/salt spray conditions.
Enclosure Deformation & Strength
Inspect deformation, strength, and sealing
performance after static load and impact.
performance after static load and impact.
Cell Fixation Strength
Verify consistency and tensile resistance of spot-welding, adhesive bonding, or bracket fixation.
FAQ
Can custom dimensions be guaranteed?
Tolerance is controlled within ±0.3mm, ensured by precision machining and assembly processes.
Will lightweight design affect structural strength?
Strength and weight are optimized through finite element analysis and material selection, maintaining impact resistance.
What level of protection can be achieved for outdoor use?
Supports IP65–IP68 protection, with optional salt spray, anti-mold, and anti-corrosion treatments.
How is consistency ensured in mass production?
Batch consistency is ensured through tooling & fixtures, first-piece inspection, and process controls (FAT / IQC / OQC).
Request Your Custom Lithium Battery Pack Evaluation
Tell us about your device and application needs.
Weíll provide a tailored evaluation covering cell design, BMS strategy, structure, thermal management and safety engineering.
Weíll provide a tailored evaluation covering cell design, BMS strategy, structure, thermal management and safety engineering.