Cell carriers, busbars, BMS PCBs, pack housings, cooling plates, and compression hardware. We build the metal and the boards your battery program is bottlenecked on — and our engineering team will help you spec them right the first time.
Cell chemistry is the famous one. The unglamorous fights are where most programs actually fail — pack-level thermal management, busbar metallurgy, and the BMS that sees and signs off on everything.
A 5 % gain on Wh/kg sells the pitch deck. A 5 % gain in cell-to-cell uniformity is what stops your field-failure rate. We hold module-level dimensional tolerance so the gain on paper survives onto the road.
Coolant chemistry, plate flatness, thermal-pad squish, busbar cross-section, and BMS sensor placement all live in one feedback loop. Treating them as separate-vendor problems is how programs lose six months in qualification.
The high-voltage interlock loop, the contactor logic, the cell-level monitor — they all have to agree on the same picture of pack health. We ship boards designed against UN 38.3, IEC 62133, and UL 2580 ahead of formal cert testing.
Most battery packs need parts from five processes. You shouldn’t need five vendors. Every part below ships from a single FabDigit cell against a single drawing pack.
Aluminum cold plates, copper laminated busbars, compression plates, and pack-mount brackets. ±0.025 mm flatness on a 600 mm cooling plate.
Learn more Pack housings · coversPack trays in 5052 / 5754 aluminum or hot-dip steel, top covers, PDU enclosures, internal partitions. Powder-coat, anodise, chromate finishes.
Learn more Cell carriers · insulatorsCell holders and stackable carriers in GF-PA66, V-0 PPS, and flame-retardant PC. UL 94 V-0 ratings as standard.
Learn more Proto carriers · jigsFast iteration on cell-holder geometry, busbar bus-jigs, leak-test fixtures. PA12 (SLS) or PEEK (SLM) when chemistry demands it.
Learn more BMS master/slaveBMS master boards, cell-level slave monitors, HV interlock loops, leak / smoke / pressure sensor boards. 4-to-12 layer ENIG.
Learn more Battery program reviewIndependent battery program reviews — cell chemistry, vendor audit, pack DFM, abuse / reliability test planning. See our LiB consultancy practice for scope.
Learn moreNumbers are working ranges across the battery programs we run in any given quarter. Coatings include treatments most US/EU shops have stepped away from due to environmental regulations — listed plainly so your design team knows what they can spec without surprise lead-time.
A representative 24s1p NMC-622 module from a recent passenger-EV program. Every callout maps to a real engineering decision we made on the customer’s drawings.
Copper strip 0.6 mm thick, ultrasonic-welded to pouch tabs. Laminated to a PEEK insulator before welding; the lamination survives the weld without delamination, audited every lot.
6082-T6 plates CNC-milled flat to ±0.05 mm. Pre-compress the pouch stack to 12 kPa; the tolerance keeps cell-to-cell expansion bounded across 2,000 cycles.
GF-30 PA66 frame, V-0 flame retardant. Holds 24 pouches in series with locating ribs that prevent in-plane drift during truck-mode vibration.
Brazed aluminum cold plate sized to the module footprint. Coolant path machined into the lid; flatness ±0.05 mm so the thermal pad compresses evenly across all 24 cells.
4-layer slave board reading per-cell voltage and two NTC thermistors. Isolated SPI link to the master, ENIG finish, 5-year solder-joint thermal-cycle life.
Single-shot disc burst at 35 kPa, routed to the pack-side smoke manifold. Captured in our DFMEA, tested per cell-vendor abuse protocol.
Six archetypes that show up on almost every pack we build. Spec lines are the working range across recent programs.
Pouch / prismatic / 4680 carrier in glass-filled PA66 or PPS. UL 94 V-0.
Copper or aluminum busbar laminated to a PEEK / PI dielectric, plated for low contact resistance.
Brazed or extruded aluminum plate sized to the module footprint, flatness ±0.05 mm.
Sheet-aluminum or steel pack tray, deep-drawn or laser-cut + welded, leak-tested.
BMS hardware with cell-level monitor, contactor driver, HV interlock, isolation barrier.
Structural pack frame for stationary storage: welded steel or extruded-aluminum chassis.
Every battery program starts with chemistry selection, and that one choice cascades into the cell format, the module topology, the busbar metallurgy, the cooling architecture, and the BMS. Below, the four chemistries we ship most often — and exactly what FabDigit builds for each.
Industry-typical numbers from recent engagements. Specific commitments live in your quote.
Aluminum cold-plate cost in particular swings hard with volume. Soft tooling pays back at ~ 500 modules; hard tooling at ~ 5,000.
Aluminum is cheap and light. Copper is conductive and weldable. Composite is exotic but solves real corrosion problems in marine packs.
Freeze-to-A-sample timeline for a 24-cell pouch module. Cell procurement is usually the long pole; we run all the metal in parallel.
Battery programs are slower than AI clusters but tighter than aerospace. Six phases, all parallelisable; we move the slow ones forward early.
Cell vendor short-list, format decision (pouch / prismatic / cylindrical), voltage / capacity targets fixed against the use case. Optional consultancy engagement (see /services/lib-consultancy/).
Engineering review on the cell carrier, busbar, and cold-plate drawings. Tooling decisions, plating decisions, abuse-test path all reviewed on a single shared call.
50 – 200 module A-samples for cell characterisation, electrical commissioning, and the first abuse coupon. Reports ship with the parts, not weeks later.
Frozen-design qualification run for UN 38.3 / IEC 62133 / UL 2580. Cells and pack-level parts share serialised genealogy so failure analysis is traceable.
Production cell stands up. SPC charts on every critical dimension; cell-vendor genealogy locked at the master-data layer. 600 – 2,400 modules / week sustained.
Field returns route through serialised pack DB. ECNs flow back into production. Second-life teardown / re-cell programs supported as a separate scope of work.
Dedicated laser-welding cell tuned for copper-on-copper pouch tabs and prismatic terminals. Coupon-tested every shift, pulsed-fibre source with closed-loop seam tracking so the weld matches the drawing every time.
A composite case study assembled from recent battery programs, anonymised. Numbers are real engagement ranges.
The customer’s existing pack supplier was hitting 14 mV ΔV at the end of the qualification cycle — outside the BMS contactor logic window. Field replacement projections forced a vendor change with 90 days of runway.
We brought the busbar lamination, the cell carrier IM tool, the compression plate, and the BMS slave board under one cell. Plating thickness was held at 1.2 ± 0.3 µm; busbar resistance variance collapsed by 4×.
B-samples passed UN 38.3 and IEC 62133 on first run. The customer is shipping the platform into B-segment cars in three EU markets.
Battery hardware is plating-heavy. Many of the historical US plating lines have closed under tightening environmental and OSHA regulation. Our domestic partners still run them daily.
Hexavalent-chromium conversion on aluminum busbars and pack housings. EPA / OSHA backlogged on US lines since 2018; we run it in a closed-loop bay with full neutralisation.
Trivalent-chromium alternative when the program needs a REACH-friendly drawing. Listed alongside Alodine in our coatings catalogue so the buyer can choose.
Selective tin dip on busbar contact zones, audited for 1.2 ± 0.3 µm thickness. Surface energy controlled to avoid solder-wicking failures during module assembly.
Vapor-deposited parylene C on BMS PCBs, sensor harnesses, and exposed copper sections facing dielectric coolant loops. Spec to 25 µm uniform.
Cathodic e-coat applied before top-coat on hot-dip steel pack trays. 1,000-hour salt-spray rating, finite-element-modelled to avoid sharp-edge thin spots.
UL 94 V-0 powder coatings on external pack housings. RAL-match colour matching standard.
We don’t. FabDigit is intentionally agnostic on cell vendors so we can give you honest DFM advice independent of any margin on the cell itself. We will help short-list and qualify cell vendors, and we will own the pack-side hardware end-to-end.
Yes. We design and manufacture against those standards from day one and ship the design history file to support your formal certification run with a third-party lab. We do not issue the certificates ourselves — that’s the lab’s job and the right side of the conflict-of-interest line.
A 5-module A-sample build is normal. Below that, we recommend the consultancy engagement at /services/lib-consultancy/ where a 1 – 3 module mule build is part of the discovery package.
Yes — both ultrasonic and laser welding for pouch tabs, and laser welding for prismatic and cylindrical busbars. Process windows are characterised per cell vendor before any production run.
We build the compression hardware, stack carrier, and busbar interfaces for solid-state programs. Cells themselves are sourced from your chemistry partner. We have early-stage tooling in place for two solid-state customers as of 2026.
We support second-life programs as a separate scope of work — serialised pack tear-down, cell health classification, and re-packaging into stationary or commercial-vehicle architectures. Talk to engineering for a custom scope.
We can deliver bring-up firmware, communication-stack scaffolding (CAN / RS485 / Modbus), and SOC / SOH baseline algorithms. Most customers bring their own production firmware; we make sure the hardware lands ready for it.
Production from partner cells in Shenzhen / Suzhou / Penang. A US onshore cell is available for export-controlled programs (e.g. defence energy storage). Talk to engineering before submitting drawings on controlled work.
Yes. Parylene C / N up to 25 µm uniform, and powder-coat in V-0 formulations for housings. Both are listed in the coatings strip above.
For programs over $1 M, yes — embedded engineer for the duration of qualification. We do this with two customers as of 2026.
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Send the cell datasheet and a pack drawing — or a sketch. Either way, you’ll have a real engineer reviewing within 24 hours and a real quote on a real schedule shortly after.
