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Flat Tube Mould Availability: How Do You Choose the Right Cross-Section Design?
Flat Tube Mould Availability: How Do You Choose the Right Cross-Section Design? Many battery pack engineers and purchasers ask early on: “Do you have an existing mould for flat tubes?” This question reveals deeper concerns—development cost, lead time, and whether the cooling efficiency meets thermal needs. Choosing the wrong cross-section design may lead to poor thermal contact, costly tooling changes, and project delays. Selecting the ideal flat tube cross-section involves balancing thermal demands, available space, contact area with cells, and fluid flow characteristics. In general, standard designs suit cylindrical cells, while customised ones are often required for prismatic cell side cooling. With rapid tooling timelines and low moulding costs, developing new flat tube profiles is a flexible, high-value option. Below, you’ll find a detailed look at what moulds are available, how to evaluate cross-section logic, when customisation makes sense, and what data you’ll need to communicate clearly with suppliers like XD THERMAL. Table of Contents What Flat Tube Mould Options Are Already Available? It’s common for clients to ask whether there are ready-to-use moulds. This question often implies they have some familiarity with battery thermal systems or have explored flat tube solutions for energy storage or electric mobility applications. XD THERMAL does maintain a library of extrusion dies for flat tubes—especially for cylindrical cell formats such as 4680 or 4695. However, many of these are protected by NDAs and are not reusable across projects. Due to the high variation in wall thickness, flow channel design, and thermal requirements, most tubes still require some degree of customisation. For instance, while 70mm, 80mm, 85mm, and even 140mm wide profiles are sometimes reused in prismatic cell side-cooling setups, internal channels and wall structures vary widely. Flat tubes are often integrated into broader battery liquid cooling systems and must be compatible with enclosure layouts….
