Internal reinforcement for heavy-duty battery housings
PRODUCT: BATTERY PACK STRUCTURAL CROSS MEMBER
Structural aluminum component designed as an internal reinforcement for the battery pack of heavy-duty trucks. The cross member ensures stiffness, load distribution and overall stability of the battery housing, contributing to safety and durability.
Mass: ~6,5 Kg
Dimension: ~400 × 130 × 80 mm
Material: Aluminum alloy EN 1706 – AC-43100 ST6
Raw part obtained per: Gravity / shell casting with porosity control (Porosity class 1.2 – DBL 4949)
Finished part obtained via: Machining + Deburring (shot-blasting or fine grinding allowed) + Dimensional and roughness inspection (Rz 100)
Challenge: ensure crack-free casting and geometric stability over lengths > 350 mm
Application: Heavy-duty truck battery pack – internal structural reinforcement
PROJECT OVERVIEW
The structural cross member is a key element inside the battery pack, responsible for load distribution and overall rigidity of the housing.
Throughout the project TECNOFOR managed:
- development of the AC-43100 ST6 aluminum casting process with controlled porosity (Porosity class 1.2)
- compliance with ISO 2768-m tolerances and shape specifications (3° draft angle, raised form up to 0.5 mm allowed)
- machining operations on complex geometries and long dimensions (>350 mm)
- deburring and finishing (shot-blasting or fine grinding allowed)
- control of surface roughness Rz 100 on functional areas
- integration of MBN 10435 markings and identification requirements (Smaragd, EVT, SAG 82321)
The result is a robust structural reinforcement, fully compliant with OEM specifications and ready for integration into the battery pack.
PRODUCT EXAMPLES
Structural cross members and aluminum components for battery packs and frames, developed and validated with European Tier1 and OEM manufacturers.
