Case Study: Battery Management System Redesign with IP67 Fastening Solution
Cleaner, scalable, and ideal for high-volume EV production.
Case Study: Battery Management System Redesign
Application Background
A global leader in electrification technologies set out to redesign its battery management system (BMS). A key requirement was the integration of an ingress protection (IP) rated solution into a metal plate used in the housing for the connector panel.
Customer Challenges
The redesign effort came with several critical challenges:
- IP Rating Compliance: The assembly required a reliable, tested IP-rated solution.
- Testing Partnership: A development partner capable of supporting IP testing was needed.
- High-Volume Production: The fastening approach had to be scalable for mass manufacturing.
- Manufacturing Cleanliness: Welding was considered a “dirty” process and not suitable for the new design.
Solution
PEM® collaborated closely through its NPD (New Product Development), Applications, and Tooling Design teams to provide a tailored, high-performance fastening solution. Key elements included:
- IP67-Rated B Nut: Delivered robust sealing performance essential to environmental protection.
- Fully Mechanical Attachment: Eliminated welding with a clinch solution combining one B nut and two clinch studs.
- System-Level Support: Supplied a complete fastening solution compatible with Haeger® installation equipment and PEM® fasteners.
- End-to-End Collaboration: Supported the customer from early sampling through mechanical and IP performance validation, ensuring a seamless transition to SOP (Start of Production).
Results & Benefits
✅ Achieved IP67 rating for the full assembly
✅ Improved cleanliness and efficiency by removing the welding process
✅ Enabled scalable, high-volume production through a repeatable mechanical fastening solution
✅ Delivered a successful prototype and transitioned to SOP on schedule
Conclusion
PEM’s integrated engineering approach and product innovation enabled the customer to meet stringent technical and operational requirements. By replacing welding with a high-integrity mechanical fastening system, the BMS achieved reliable environmental sealing, improved process cleanliness, and scalability for next-generation electric vehicles.
Why Partner with PennEngineering®?
Engineering Integration
- Application engineering support
- Quick prototyping and validation
- Reduced design iterations and time-to-market
Supply chain agility
- Forecast-driven capacity planning
- Expedited lead times and buffer stock
- 24/7 global support with CM-level coordination
sustainability alignment
- Material traceability and responsible sourcing
- Design-for-sustainability consultations
- Joint carbon footprint reduction initiatives
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