Novelis Creates First Aluminum Sheet Battery Enclosure for Mass Electric Vehicle Production

May 1, 2019

William Kucinski

Battery weight and power density is a major design consideration when it comes to electric and hybrid-electric vehicles. To reduce platform weight for next-generation electric vehicles, Atlanta-based Novelis, Inc. (Novelis) has used direct feedback from industry partners and automotive design engineers to develop the first aluminum sheet battery enclosure.

Beyond leveraging the corrosion resistant properties of aluminum, the enclosure is 50 percent lighter and significantly cheaper than conventional steel sheet designs. The component materials are also easily recyclable and having better thermal conductivity, which helps keep battery cells cool and increases its lifespan as compared to steel designs.

According to Novelis, it matches the best energy density in the industry by enabling more than 160 watt-hours per kilogram, an extremely efficient design for original equipment manufacturers (OEMs) and Tier 1 battery pack manufacturers.

William Kucinski is content editor at SAE International, Aerospace Products Group in Warrendale, Pa. Previously, he worked as a writer at the NASA Safety Center in Cleveland, Ohio and was responsible for writing the agency’s System Failure Case Studies. His interests include literally anything that has to do with space, past and present military aircraft, and propulsion technology.

Contact him regarding any article or collaboration ideas by e-mail at This email address is being protected from spambots. You need JavaScript enabled to view it..