Speed, quality, and confidence are critical in EV battery manufacturing. This session will demonstrate how early-stage simulation for welding, forming, and additive processes can support faster decisions, reduce downstream errors, and strengthen collaboration between engineering, production, and costing teams.

Key takeaways

• Predict thermal and mechanical effects such as heat input, distortion, and residual stress before shop-floor trials.
• Control springback, thinning, and wrinkling to reduce die rework and protect part tolerances.
• Manage additive distortion and support structures to meet mass requirements.
• Integrate manufacturability and cost drivers into engineering decisions.
• Build a lightweight digital twin to support line readiness, quality planning, and production audits.

Expected Outcomes

Faster alignment between engineering, costing, and production decisions.		Fewer iterations caused by late discovery of distortion or springback.		Clearer handovers from simulation to line readiness activities.

Who will find this valuable

For Automobile Manufacturers

• Improve launch quality and ramp-up speed by anticipating distortion and thinning issues early.
• Support process audits and supplier readiness with simulation-based validation.
• Enable faster engineering-to-manufacturing alignment through lightweight digital twins.

For Auto Suppliers

• Enhance RFQs and project bids with evidence-based rework and fixture estimates.
• Visualise springback and weld effects before committing to tooling.
• Demonstrate compliance with OEM simulation and validation requirements.

For EV Companies

• Accelerate project timelines with every go/no-go simulation-driven decision.
• Align engineering and production more closely to minimise late changes and disruptions.
• Develop reusable workflows that scale across battery variants and platforms.

For Battery Manufacturers

• Identify and mitigate heat-sensitive and propagation-critical risks during joining and assembly.
• Manage heat input and residual stresses to support durability and sealing targets.
• Create pre-trial checklists that reduce scrap and rework on critical operations.

For Manufacturing Engineers and Simulation Leads

• Map each decision to the minimum model, required inputs, and outputs to review.
• Calibrate models with simple artefacts such as gauge comparisons, distortion checks, and arc curves.
• Hand off clear actions to production with fixture adjustments, compensation moves, and support plans.

Turn Simulations into Decisions

Make your next manufacturing decision with evidence. Move simulation forward in welding, forming, and additive processes to reduce trial loops, improve quality, and ensure seamless handovers to production.