“At Sertec, we believe the best partnerships are built on trust, shared ambition, and a relentless focus on the customer. Our collaboration with AESC is a great example of that. From day one, it’s been about working side by side to understand their needs and deliver solutions that genuinely add value. Supporting the Sunderland site with localised battery cover components isn’t just about supply—it’s about being a responsive, reliable partner who’s invested in their success. Together, we’re not just building components; we’re helping power the future of sustainable solutions.” Dave Steggles
Localisation with Purpose: Customer Vision Meets Sertec’s Values
When AESC approached us with a bold ambition—to localise the production of EV battery cases in support of nearshoring, cost efficiency, and environmental sustainability—we saw more than a project. We saw an opportunity to bring our values to life: Success, Response, Teamwork & commitment.
Our commercial team quickly engaged with AESC to explore how Sertec could support their localisation goals. From the outset, our shared commitment to sustainability and operational efficiency laid the foundation for a partnership built on trust and progress.
Sertec now manufactures battery cover components for AESC, which are essential parts of the battery packs used in electric vehicles. These covers help protect the internal battery cells, ensuring safety, durability, and performance. We are currently working with AESC to support the next generation of cases.
Who is AESC?
AESC is a global leader in lithium-ion battery technology, serving the electric vehicle and energy storage sectors. Headquartered in Yokohama, Japan, AESC operates across key regions including Europe, China, the U.S., and the U.K., with a strong focus on localised production to support OEMs and regional sustainability goals.
One of its flagship facilities is the Sunderland gigafactory, which plays a vital role in supplying EV batteries to manufacturers across the UK and Europe. As a Tier 2 supplier, Sertec supports this site through the localisation of battery cover components. This partnership reflects our shared commitment to innovation and sustainability
What Was Our Role?
As a strategic manufacturing partner, Sertec led the industrialisation of the battery case programme from proof of concept to full SOP in under 10 months.
This included:
- Tooling design and procurement
- Process development and validation
- Seamless implementation across stamping, clinching, cleaning, and packing—with zero-touch automation
Our team’s ability to deliver at pace while maintaining quality and cost targets is a testament to the depth of expertise across engineering, commercial, and operations.
Localisation strengthens sustainability in automotive by reducing environmental impact, enhancing supply chain resilience, and supporting regional economies. By manufacturing components closer to final assembly plants, companies like Sertec help cut down on long-distance transportation, which lowers carbon emissions and energy use. It also enables faster response times, reduces overproduction and waste, and supports just-in-time manufacturing practices. In partnerships like ours, localisation means we can dispatch components directly to their site, ensuring efficiency while aligning with broader sustainability goals. Beyond logistics, localisation fosters innovation through closer collaboration, and it supports local job creation—making sustainability not just an environmental goal, but a social and economic one too.
What Was the Biggest Engineering Challenge?
The most complex challenge? Time.
Achieving volume production in a short period was critical for the customer. We worked tirelessly to ensure the B4 variant achieved this within 10 months, requiring precision planning, cross-functional coordination, and relentless execution. From tooling trials to supplier visits across Europe, our engineers worked tirelessly to meet every milestone.
We overcame resource constraints, quality control bottlenecks, and packaging complexities—all while maintaining alignment with AESC’s evolving requirements
How Did We Work With the Customer to Overcome It?
Our approach was simple but powerful: understand, collaborate, and respond with pace.
We embedded ourselves in AESC’s vision, aligning our processes to their expectations. From the first meeting to the final production run, our teams operated as one—sharing knowledge, adapting quickly, and delivering solutions that exceeded expectations
What Have Been the Most Successful Elements?
Customer Satisfaction: We met every specification and delivered a new product line that was central to AESC’s UK operations.
Account Growth: Our success has led to additional engineering projects with additional vehicles that have evolved our process to include insulation.
Team Excellence: Our people—engineers, planners, operators—brought Sertec’s values to life, proving that innovation is not just about technology, but about people working together with purpose.
Looking Ahead
Today, Sertec continues to support AESC with new solutions and expanded capabilities. From aluminum and steel battery covers to advanced automation, we’re proud to be part of the journey toward a cleaner, smarter future.
This project is more than a milestone—it’s a blueprint for how Sertec partners with customers to turn ambition into achievement
This is the Sertec way in action — responding to our customers’ needs with pace and integrity. Through precision and reliability, we deliver engineering solutions that not only meet today’s demands but also lead the way in sustainable innovation. Our commitment to collaboration, agility, and excellence is what drives us forward — and keeps our customers at the heart of everything we do.
This Is the Sertec Way in Action
Responding to our customers’ needs with pace and integrity. Through precision and reliability, we deliver engineering solutions that not only meet today’s demands but also lead the way in sustainable innovation. Our commitment to collaboration, agility, and excellence is what drives us forward — and keeps our customers at the heart of everything we do.
