{"id":3667,"date":"2026-08-05T09:52:44","date_gmt":"2026-08-05T07:52:44","guid":{"rendered":"https:\/\/www.tecnoforsrl.com\/?p=3667"},"modified":"2026-08-05T09:58:51","modified_gmt":"2026-08-05T07:58:51","slug":"case-study-battery-pack-structural-cross-member","status":"publish","type":"post","link":"https:\/\/www.tecnoforsrl.com\/en\/case-study-battery-pack-structural-cross-member\/","title":{"rendered":"Case Study &#8211; Battery Pack structural cross member"},"content":{"rendered":"<h2>Internal reinforcement for heavy-duty battery housings<\/h2>\n<h3><b>PRODUCT: BATTERY PACK STRUCTURAL CROSS MEMBER<br \/>\n<\/b><\/h3>\n<p>Structural aluminum component designed as an <strong>internal reinforcement for the battery pack<\/strong> of heavy-duty trucks. The cross member ensures stiffness, load distribution and overall stability of the battery housing, contributing to safety and durability. <\/p>\n<p><strong>Mass:<\/strong> ~6,5 Kg<br \/>\n<strong>Dimension:<\/strong> ~400 \u00d7 130 \u00d7 80 mm<br \/>\n<strong>Material:<\/strong> Aluminum alloy EN 1706 \u2013 AC-43100 ST6<br \/>\n<strong>Raw part obtained per:<\/strong> Gravity \/ shell casting with porosity control (Porosity class 1.2 \u2013 DBL 4949)<br \/>\n<strong>Finished part obtained via:<\/strong> Machining + Deburring (shot-blasting or fine grinding allowed) + Dimensional and roughness inspection (Rz 100)<br \/>\n<strong>Challenge: <\/strong>ensure crack-free casting and geometric stability over lengths &gt; 350 mm<br \/>\n<strong>Application:<\/strong> Heavy-duty truck battery pack \u2013 internal structural reinforcement<\/p>\n<h3><b>PROJECT OVERVIEW<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">The structural cross member is a key element inside the battery pack, responsible for load distribution and overall rigidity of the housing.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Throughout the project TECNOFOR managed:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\">development of the <b>AC-43100 ST6 aluminum casting process<\/b> with controlled porosity (Porosity class 1.2)<\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\">compliance with <b>ISO 2768-m tolerances<\/b> and shape specifications (3\u00b0 draft angle, raised form up to 0.5 mm allowed)<\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>machining operations<\/b> on complex geometries and long dimensions (>350 mm)<\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>deburring and finishing<\/b> (shot-blasting or fine grinding allowed)<\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\">control of <b>surface roughness Rz 100<\/b> on functional areas<\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\">integration of <b>MBN 10435 markings<\/b> and identification requirements (Smaragd, EVT, SAG 82321)<\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">The result is a robust structural reinforcement, fully compliant with OEM specifications and ready for integration into the battery pack.<\/span><\/p>\n<h3><b>PRODUCT EXAMPLES<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">Structural cross members and aluminum components for battery packs and frames, developed and validated with European Tier1 and OEM manufacturers.<\/span><\/p>\n<h3><b>NEXT PROJECT<\/b><\/h3>\n<p><a href=\"https:\/\/www.tecnoforsrl.com\/en\/case-study-cross-member\/\"><span style=\"font-weight: 400;\">Cross Member \u2013 Rear engine support bolted to the main frame<\/span><\/a><\/p>\n","protected":false},"excerpt":{"rendered":"<p>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&#8230;<\/p>\n","protected":false},"author":2,"featured_media":1876,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"inline_featured_image":false,"footnotes":""},"categories":[31],"tags":[],"table_tags":[],"class_list":["post-3667","post","type-post","status-publish","format-standard","has-post-thumbnail","category-case-study-en"],"_links":{"self":[{"href":"https:\/\/www.tecnoforsrl.com\/en\/wp-json\/wp\/v2\/posts\/3667","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.tecnoforsrl.com\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.tecnoforsrl.com\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.tecnoforsrl.com\/en\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/www.tecnoforsrl.com\/en\/wp-json\/wp\/v2\/comments?post=3667"}],"version-history":[{"count":3,"href":"https:\/\/www.tecnoforsrl.com\/en\/wp-json\/wp\/v2\/posts\/3667\/revisions"}],"predecessor-version":[{"id":3701,"href":"https:\/\/www.tecnoforsrl.com\/en\/wp-json\/wp\/v2\/posts\/3667\/revisions\/3701"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.tecnoforsrl.com\/en\/wp-json\/wp\/v2\/media\/1876"}],"wp:attachment":[{"href":"https:\/\/www.tecnoforsrl.com\/en\/wp-json\/wp\/v2\/media?parent=3667"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.tecnoforsrl.com\/en\/wp-json\/wp\/v2\/categories?post=3667"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.tecnoforsrl.com\/en\/wp-json\/wp\/v2\/tags?post=3667"},{"taxonomy":"table_tags","embeddable":true,"href":"https:\/\/www.tecnoforsrl.com\/en\/wp-json\/wp\/v2\/table_tags?post=3667"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}