The heart of every Electric Vehicle is the battery pack. And the armor protecting that heart is the Deep Drawn Battery Can.
Whether it's a cylindrical 4680 cell (Tesla style) or a large Prismatic cell (BYD style), the manufacturing challenge is the same: Make it lighter, make it cheaper, and make millions of them perfectly.
1. Cylindrical (4680) vs. Prismatic
Cylindrical (e.g., 4680)
The Challenge: Height-to-Diameter ratio. A 4680 cell is 80mm tall. Drawing this in one go is impossible.
The Process: Multi-stage Deep Drawing + Ironing. We draw the cup, then "iron" the walls to thin them out while keeping the bottom thick for the burst disk.
Prismatic (Rectangular)
The Challenge: Corner Radius. Square corners are stress concentrators. The material wants to tear at the corners.
The Process: We use a specialized "cushion" system in the press to control material flow, ensuring the corners don't thin out dangerously (a common aluminum defect).
2. The "Ironing" Secret
How do you get a can with a 0.3mm wall but a 1.5mm bottom? You can't do that with standard stamping.
What is Ironing?
Ironing is a post-draw process where we force the cup through a ring that is smaller than the cup's outer diameter.
This squeezes the wall, thinning it out and elongating the can, while leaving the bottom untouched. This is how soda cans are made, and it's how we make EV battery cans.
3. Cleanliness is Godliness
A single metallic particle inside a battery can cause a short circuit and a fire.
- ✓VDA 19 Standard: We use automated washing lines with ultrasonic cleaning to ensure particle counts meet strict automotive standards.
- ✓Oil-Free: We use evaporative lubricants that leave zero residue, or we wash parts in a vacuum solvent system.
Scaling Up for EV Production?
We have the capacity to produce 5 million cans per month. Let's discuss your ramp-up plan.
Discuss EV Battery Projects