EV Solutions

The electric vehicle revolution demands more than just components; it demands innovative manufacturing solutions at an ever-increasing scale.

We stand as a leading specialist in Europe in applying advanced technologies and processes to high EV solutions. We’re working to drive the evolution of the UK electric vehicles industry, making high volume EV production not just a goal, but a tangible reality for our partners.

Our expertise is in turning complex EV component concepts into manufacturing realities. We understand that bringing next generation electric vehicles to market requires more than an innovative design – it needs robust, scalable production strategies.

We work closely with our valued partners from the very earliest stages. We take your vision, generate a manufacturing concept, prove the concept, and apply our extensive Design for Manufacture (DFM) knowledge to ensure every part is optimised for efficient, high volume production. When our partners come to us with a design challenge for intricate components, we pride ourselves on collaborating to develop solutions that leverage our advanced processes, ensuring seamless scalability.

Battery Enclosures: Battery Cell Covers, Cases and Busbars

The battery cell cover, case or bus bar is more than just an individual component. It’s a critical, high precision structural component at the heart of every electric vehicle. Our expertise in precision metal forming and advanced automated assembly addresses the unique and incredibly demanding requirements of these vital components. We recognise the immense challenge of fitting complex EV battery components within incredibly confined spaces, where accuracy must be very high to prevent tolerance stack and ensure optimal performance.

To meet this demand, in conjunction with our trusted partners, we have pushed the boundaries of manufacturing.

  • We’ve developed new press-forming technology to increase the processing speed and accuracy of the battery cover, case and busbar.
  • This includes developing highly effective flattening processes, both as standalone operations and seamlessly integrated within our assembly lines.

These innovations ensure that battery enclosure components are not just strong and durable, but incredibly flat and precise, guaranteeing a perfect fit and performance.

The safety, integrity, and reliability of a battery cell cover, case and busbar is paramount. This is why our quality control systems are built on the principles of ‘Right First Time’, utilising integrated laser measurements and advanced vision systems.

Unlike traditional methods that require components to be removed from the assembly line for inspection, our technology performs inline measurement and real-time data collection. This means every single component is meticulously inspected as it is manufactured, providing the ultimate assurance that all battery enclosures meet the most stringent dimensional accuracy and performance standards.

Lightweight Design: Maximising EV Performance

For electric vehicles, lightweight design is crucial. The lighter an EV’s components, particularly the battery, the more efficiently it converts stored energy into range, giving drivers more miles on a single charge.

Given that electric cars are as much as 10 – 30% heavier than traditional combustion engine vehicles, every microgram saved in component weight translates to enhanced performance and range.

As EV solutions leaders, our expertise lies in delivering components that are incredibly lightweight but also possess the durability to withstand significant crash impact. We leverage our deep understanding of advanced lightweight materials and precision manufacturing to optimise weight through material selection and pressing processes.

By innovating in lightweighting, we help our partners to push the boundaries of EV design, contributing to electric vehicles that are safe and more energy efficient.

Connect with our EV solution experts to discuss high-precision battery and lightweighting manufacturing for the evolving Electric Vehicles industry.

Locations

Sertec's strategic positioning within europe and our global partnerships enable us to best support our customers across the world.

Sertec Auto Structures Wincaster House

11 Gorsey Ln, Coleshill, Birmingham B46 1JU, United Kingdom

Sertec Auto Structures Heavy Stampings

11 Gorsey Ln, Coleshill, Birmingham B46 1JU, United Kingdom

Sertec Aluminium Structures

Redfern Park Way, Birmingham B11 2BF, United Kingdom

Sertec Auto Structures Hungary

Ászár, Köztársaság u. 15/A, 2881 Hungary

Sertec China

Room 2102, Diwang Plaza Commercial Centre office Building Chang Qing South Road NO.303, Chang'An, Town, DONGGUAN CITY, GUANGDONG, CHINA

Capabilities

Pressings & assembly

Coated components

EV solutions

Supply chain & logistics

Robotics & digital manufacturing

Tooling manufacture

Innovation Stories

From Career Search to Continuous Improvement Engineer Apprentice

From Apprenticeship to Sertec’s Youngest Project Manager

From Early Enthusiasm to Trainee CAD Engineer

From Engineering Apprentice to Project Manager

Localisation in Action

Investment In Action

Diversification in Action

01/07

02/07

03/07

04/07

05/07

06/07

07/07