Advanced Liquid Cooling Solutions For EV & Energy Storage
Battery Cooling Plate Manufacturer for EV & ESS Projects
Custom cold plates with DFM/CFD support and volume-ready manufacturing. From Thermal Design (DFM) to Mass Production.
- 50,000+ Monthly Capacity
- 10+ Years (OEM Experience)
- 100% (Leak Testing)
Quick Navigation :
Let’s Engineer Your Solution
We bridge the gap between design and mass production. Here is what we need to transform your concept into a manufacturable reality.
A. What we need from you
B. What you will get
Standard deliverables to accelerate your internal approval:
- Process recommendation
Best fit: Hydroforming, Extrusion, FSW, or Machining.
- DFM Feedback
Detailed risk points & manufacturability suggestions.
- Quotation
A quotation (unit price based on your provided specs and volume band), including lead-time assumptions
- Prototype-to-Volume Plan
Milestones for samples and mass production ramp-up.
- Response SLA: 12h feedback
- Confidentiality: NDA available / drawing protected
- Quality system: IATF 16949
- Validation: leak/pressure/insulation tests (project-based)
Choose the Right Cooling Plate Process in 30 Seconds
| Parameters | Hydroforming | Extrusion | FSW | Machining |
|---|---|---|---|---|
| Mechanical Strength | Good | Excellent | Excellent | Good |
| Tooling Investment | Yes | Yes | No | No |
| Lead time for OTS | 45 days | 30-45 days | 30-45 days | 25-35 days |
| Dimension (mm) | L 150-2900 W 50-1900 |
L not limited W 50-1500 |
L 200-2200 W 50-1500 |
L 150-800 W 100-450 |
| Applications | EVS, ESS, Solar, eVTOL | EVS, ESS, Heavy duties | EVS | EVS |
| Ideal For | Mass Production | Mass Production | Medium Volume / High Performance | Prototyping / Small Batch |
Still not sure which process fits your battery pack? XD Thermal combines 10+ years of OEM experience with comprehensive thermal engineering. From flow simulation (CFD) to DFM analysis, our engineers will recommend the most cost-effective solution for your specific thermal goals.
Mates to be mated for Your Cold Plate
There are multiple mating parts that work together with cooling plates and battery cells. Each part mated and assembled in every battery pack.
Spigots (coolant inlet & outlet)
Quick Connectors
Thermal interface
Pipe Lines
Integrated Manufacturing: From Design to Validation
Our Factory by the Numbers: 50,000+ Monthly Capacity | 99.8% Pass Rate | IATF 16949 Certified
01. Design & Simulation (DFM/CFD)
- Thermal Analysis: Optimization of flow channels to minimize pressure drop (< 30kPa) and enhance thermal uniformity (ΔT < 2°C).
- Free DFM: We review your drawings to reduce tooling costs and ensure manufacturability before tooling kick-off.
02. Precision Forming & Machining
- Diverse Processes: In-house 500T-3000T Stamping Presses, Extrusion lines.
- CNC Accuracy: 30+ CNC centers ensuring flatness tolerance within ±0.05mm for mounting surfaces.
03. Advanced Brazing Technology
- Controlled Atmosphere: Continuous CAB furnaces ensure robust metallurgical bonding.
- Vacuum Brazing: Available for complex structures requiring flux-free joints.
04. 100% Validation & Testing
- Leakage Policy: 100% Helium mass spectrometry leak detection for every single plate.
- In-House Lab: Burst pressure, Thermal cycle, and Salt spray testing performed internally.
- Traceability: Laser marking on each plate for full lifecycle tracking.
Success Cases
Liquid Cooling Solution for Commercial EV Battery Pack
A leading EV manufacturer required a cooling solution for their new prismatic cell pack with high heat flux density.
The Challenge
● Strict space limitation (Height < 7mm).
● Limit Temp Difference (ΔT) < 4°C under fast charging.
Our Solution
● DFM Optimization: Transformed the original design into a multi-channel brazed aluminum plate to increase heat transfer area.
● Simulation: Used CFD to optimize the internal flow path, balancing pressure drop and cooling efficiency.
The Result
● Achieved ΔT < 2.2°C at 2C charging rate.
● Pressure drop controlled within 18kPa.
● Passed 1000-hour vibration & thermal shock tests.
1800mm Large Format Cold Plate for ESS Container
A global energy storage integrator needed robust cooling plates for their 5MWh liquid-cooled container system.
The Challenge
1. Large dimensions (1800mm x 800mm) risk of high-temp deformation during brazing.
2. Zero tolerance for leakage over a 10-year lifespan.
Our Solution
1. Process: Utilized our large-format vacuum brazing furnace with custom fixtures to control flatness within ±1mm.
2. Validation: Implemented 100% Helium Mass Spectrometry leak detection (Leak rate < 1× 10^{-6} mbar.l/s).
The Result
● Successfully delivered 5,000+ units
● Helped the client reduce assembly time by 20% due to precise mounting hole tolerance.
Rapid Prototyping: From Concept to Sample in 15 Days
A clean-energy startup needed a custom prototype for their battery thermal management system verification.
The Challenge
1. Extremely tight schedule (3 weeks)
2. Avoid expensive tooling investment.
Our Solution
1. Technology: Selected CNC Machining + Vacuum Brazing process to bypass tooling time.
2. Engineering: Provided free DFM feedback to reduce wall thickness, cutting weight by 15%.
The Result
● Samples shipped in 15 days.
● Performance verified perfectly, leading to a mass production contract 6 months later.
