Portfolio/02 — CAD / TEAM PROJECT

CAD / SOLIDWORKS · HYPERBAT TEAM PROJECT

A smoother connection for EV busbars.

This was a team project exploring battery-pack manufacturing for the Lotus Evija. My contribution was the SolidWorks model: a repeated cell-connection layout and mounting outline for the busbar concept.

SolidWorksEV battery systemsBusbar conceptTeam project
Full isometric SolidWorks model of the repeated EV battery busbar and cell connection layout
FULL SOLIDWORKS MODEL / REPEATED CELL CONNECTION LAYOUT

01 / THE PROBLEM

Small gaps, serious consequences

The team explored contamination and corrosion issues in copper busbar manufacture for the Lotus Evija battery pack. Angular crevices around cell connections can collect particles, which may affect weld quality and electrical performance.

~10%The project brief noted that around 10% of produced copper busbars fail on average over a three-month period.

02 / THE DESIGN MOVE

Replace the angular crevice

The team proposed a smoother, curved opening at the tab-cell interface to reduce sharp crevices. These cross-sections show the design intent; they are concept views, not test results.

Current tab-cell cross-section, showing angular crevices beside the battery cell
Current geometryAngular gaps at the cell connection can create spaces where contaminants may collect.
Proposed tab-cell cross-section with a smoothed, curved opening
Proposed geometryA smoothed, curved opening is intended to reduce those crevice areas.

TEAM DESIGN CONCEPT / CURRENT VS PROPOSED

03 / THE CAD

Communicating the full layout

My contribution was the full repeated connection layout and mounting outline, modelled in SolidWorks. The complete view makes the spacing, repeated circular features and overall carrier shape easy to review alongside the proposed cross-section change.

The model is a concept for design discussion. It does not demonstrate electrical or thermal performance, prove contamination reduction, or represent a released manufacturing drawing.

04 / TEAM RECOMMENDATIONS

Design beyond the geometry

The team also considered material, corrosion protection and process improvements:

01 / MATERIAL

Consider aluminium

The team considered aluminium instead of copper. Its estimate showed a 46% mass reduction after increasing thickness by 56% to compensate for lower conductivity.

02 / PROTECTION

Protect the surface

Retain nickel plating and investigate an added polymer electrostatic coating to improve corrosion protection on the busbar surfaces.

03 / PROCESS

Control cleanliness

Improve inspection and cleaning controls, including non-destructive testing and more consistent rinse-water and tank hygiene.

Team project: the manufacturing research and recommendations were developed collectively. My individual contribution shown here is the SolidWorks CAD model. The proposed geometry and material changes would need manufacturing review and electrical, thermal, corrosion and contamination testing.