TGM Lightweight Solutions

TGM Lightweight Solutions

The National Manufacturing Institute Scotland (NMIS) collaborated with German lightweighting specialists TGM Lightweight Solutions to design a car battery concept that can reduce weight, production costs and vehicle CO2 emissions, while providing an improved battery life expectancy, without compromising on power

What challenge did TGM face?

Automotive manufacturers must meet customer demands for increased space, power, and features within their vehicles while contending with tightening CO2 regulations and remaining competitive. As we move towards net-zero global emissions by 2050 and see an increased appetite for electric vehicles, the need for efficient low-cost batteries has never been greater.

How did NMIS help?

TGM Lightweight Solutions devised a patented design for a starter battery using a LiFePO4 battery cell. They collaborated with the NMIS Design Engineering team across all stages of concept creation including design analysis, weight reduction optimisation, method of manufacturing assessment, and overall cost estimation, focusing on a starter battery for a BMW F15, which is a popular mid-size luxury SUV. The team identified that a technology change from lead to lithium iron phosphate would create a lighter and smaller battery, and devised an improved lightweight design for the modular battery case focusing on reduced weight and manufacturing costs. Combining expertise and embedding NMIS manufacturing knowledge early into the design process ensured the rapid development of a proven concept that is highly cost-effective, sustainable, and ready for transformation into an industry demonstrator.