Production tooling for the swappable EV battery pack cover — taking the enclosure from prototype part to a moulded production component. Second tooling programme after the fan rotor die, applying the same design-for-tooling discipline at larger scale.
Cover geometry was finalised with draft, wall-thickness and shrinkage allowances, then the tool was designed — core and cavity split, insert layout, core-pin placement, cooling and ejection. Machining was carried out with the tooling supplier with inspection at key stages, followed by assembly, tryout shots and dimensional verification of moulded covers against the pack assembly.
Core pins & inserts
Die plate
Machined components
Assembled tool
Tool handling
End result — production pack
A battery cover is a much larger tool than a fan rotor die — handling, lifting points and bench logistics at the supplier became real engineering considerations, not afterthoughts. Eye-bolt positions and strap points were designed in.
The cover's sealing faces interface directly with pack waterproofing. Those surfaces got the tightest tolerance attention through machining and tryout, since a leaking battery pack is a field failure, not a cosmetic one.
Production tooling delivered and proven for the battery pack cover — repeatable moulded covers feeding the vehicle programme's certification builds and ramp plan.