TGM special: Modular Lightweight Starterbattery

The concept

Besides our passion for analysing existing vehicles in our lightweight garage, we also get creative ourselves designing new lightweight concepts. Together with our partners, the National Manufacturing Institute Scotland, Litewerks and the Koller Group, we have developed a modular modular lightweight starter battery to replace conventional heavy lead lead batteries. The starting point is the technology change to lithium iron phosphate, as the stable voltage plateau above the capacity enables efficient use.

The idea

Starting with lithium iron phosphate cylindric cells, which are accommodated in the cell holder at their stiff end points, the housing was designed accordingly. This accommodation allows the cell surface to be cooled. The cells are arranged in a pack-tight manner in the cell holder and cut-outs provide installation space for cable routing, the battery management system and other components.

The cell holders support the enclosure and thus reduce the required wall thickness, as forces can be transferred ideally. The prismatic shape of the enclosure also increases its inherent rigidity. In an application with parallel housings, the slopes allow the batteries to slide on top of each other and thus reduce the crash load.

The modular design with a high number of of common parts opens up economies of scale and enables dimensioning according to the requirements. For an application with only one module a cover is placed on the module, whereas a connector combines two modules. When mounting with a clamp, forces are also transmitted via the connector. The snap connections allow to open the battery without destroying it.

The demonstrator

The first demonstrator of the modular lightweight starter battery was created from stereolithographically manufactured housing parts, a battery management system and filled dummy battery cells. To ensure optimal production, the wall thicknesses were adjusted and the snap connections were glued.

One module in the version shown corresponds to the equivalent of a 70 Ah lead starter battery. Two modules have the same length and width of a 90 Ah lead-acid battery and offer a standard-compliant installation.

The Lightweighting Effect

The weight saving on the 2016 X5 Hybrid (F15) reference vehicle, according to the Casestudy performed, amounts to over 33 kg compared to the baseline condition and can be increased to over Effects to be increased to over 40 kg. Also, 10 L of installation space is freed up is freed up and the service life is tripled. The lightweight construction costs at the reference fall from 23.1 and 18.7 € respectively, including the secondary secondary effects to 15.6 and 12.5 € respectively.


February 04 2021

The TGM & NMIS collaboration: A show-case study of estimating lightweight cost for a LiFePO4 starter battery

TGM Lightweight Solutions

February 18, 2021

This is what lightweight construction looks like: Innovative battery concept saves weight, resources and costs

Network Lightweight Metal Brandenburg

04 March 2021

Case studies: TGM Lightweight Solutions

National Manufacturing Institute Scotland

March 17, 2021


Koller Group

April 12, 2021

Product 2021 - Battery concept in system lightweight construction

Hanover Fair

April 19, 2021

Design of a starter battery suitable for lightweight construction

Presentation - eMove 360° 

April 22, 2021

VDI-Z 05|2021


April 28, 2021

Contribution to the series: Lightweight Solutions for a Net Zero world


May 19, 2021

Lightweight Engineering - lightweight solutions for the mobility of the future

Hanover Fair

May 20, 2021

Marklines Hannover Fair Highlights

Hanover Fair

May 25, 2021

Hannover Messe - LinkedIn

Hanover Fair

May 31, 2021

Solutions for electromobility - evaluating lightweight construction costs using the example of a modular battery concept


June 23, 2021

Cross-Industry Dialog | Are the existing design and simulation tools sufficient?

Presentation - Fraunhofer IAP

August 04, 2021

ThinKing August 2021: A battery reinvents itself - Lightweight, flexible and durable

Lightweight BW


industrial box

Press Blog

News Blast

Technology Box

News Research

it it Prof

06 August 2021

Market Steel

October 21, 2021

Press box

October 29, 2021

ATZ Lightweight Special

ATZ worldwide

31 October 2021 - 12 November 2021

Lightweighting Forum

Exhibition - Accompanying the 26th UN Climate Change Conference of the Parties in Glasgow

08 November 2021

Lightweight battery concept drives down emissions


November 11, 2021

Lightweight battery housing

Lightweight showroom

More like this:

You find additional TGM Articles here.

WordPress Cookie Notice by Real Cookie Banner