EV Battery Pack & Enclosure Engineering
Compact, Safe, and Manufacturable Battery Packaging for E-Bikes, Two-Wheelers & Light EVs
Designing an electric vehicle battery pack requires more than wiring cells together—it demands tight mechanical packaging, structural vibration resistance, thermal dissipation, and seamless fitment inside constrained vehicle frames.
At Engineer's Cubicle, we combine parametric 3D CAD engineering with in-house Additive Manufacturing to design, prototype, and validate custom battery layouts and enclosures for electric bicycles, two-wheelers, conversion kits, and specialty mobility platforms.
- Cylindrical & Prismatic Layouts: Optimized series-parallel arrangements for 18650, 21700, 32700, and LFP prismatic cells.
- BMS & Harness Integration: Dedicated mounting bays for Smart BMS units, contactors, fuses, and waterproof charging ports.
- Frame-Specific Ergonomics: Swappable or fixed battery casings tailored to your exact chassis geometry.
Why Prototype EV Packs with 3D Printing?
Jumping straight to sheet-metal tooling or injection molding for a new battery pack is expensive and risky. Using DfAM and 3D printing, we help you:
- 3D print custom honeycomb cell spacers and busbar routing guides in hours.
- Test physical fitment inside your e-bike or scooter chassis before committing to hard tooling.
- Iterate seal grooves, mounting brackets, and connector cutouts rapidly at a fraction of traditional prototyping costs.
Our EV Battery Design Capabilities
End-to-end mechanical design and rapid prototyping tailored for EV startups, retrofitters, R&D teams, and custom vehicle builders.
Cell Layout & Space Claim
3D CAD arrangement of cells to maximize energy density within irregular frame triangles, floorboards, or under-seat compartments.
Custom Cell Holders
Design and 3D printing of custom interlocking cell matrices with integrated nickel-strip reliefs, voltage-sense wire channels, and shock isolation.
Thermal & Spacing Design
Engineering uniform cell-to-cell air gaps, thermal pad compression zones, and heat-dissipation paths to prevent localized hot spots.
Enclosure & Casing CAD
Designing rugged outer casings for 3D printing, sheet-metal fabrication, or thermoforming—complete with gasket grooves and mounting bosses.
From Concept to Validated Prototype
Our structured mechanical engineering workflow ensures your battery pack is safe to assemble, easy to service, and ready for production.
-
01 Electrical Specs & Frame Space-Claim
Share your target voltage/capacity (e.g., 48V, 60V, 72V), preferred cell chemistry/form-factor,BMS dimensions, and vehicle frame measurements or CAD step files.
-
02 3D Cell Matrix & Internal Packaging
We model the complete internal architecture in CAD—orienting series groups for short, low-resistance busbar runs and isolating the BMS and power cabling.
-
03 Enclosure Design for Manufacturing (DfM / DfAM)
We engineer the outer housing around your target manufacturing method—whether that's a 3D-printed functional housing for low-volume builds or bent sheet metal/plastic for scale.
-
04 3D-Printed Fitment & Assembly Prototyping
We 3D print physical prototypes of the cell holders, end-caps, and enclosure sections in durable engineering filaments (such as PETG/ABS) so you can verify cell tolerances and vehicle mounting.
-
05 Final CAD & Production File Handover
Receive production-ready 3D CAD models (STEP/IGES), 2D manufacturing drawings, DXF flat patterns for sheet metal or laser-cut busbars, and print-ready files.
Applications We Support
Whether you are building a custom one-off electric bicycle or developing a commercial light electric vehicle platform, we tailor the pack geometry to your exact use case:
- Electric Bicycles & Cargo E-Bikes
- Electric Scooters & Motorcycles
- Swappable Battery Modules
- Robotics, AGVs & Portable Power Packs
- Student Motorsport & R&D Prototypes
Need standalone CAD design or both design and 3D-printed prototyping? We support clients in Pune and remotely worldwide.
Building an Electric Vehicle or Custom Battery Pack?
Send us your cell configuration, chassis dimensions, or rough sketch on WhatsApp. We'll help you design a compact, durable battery enclosure and prototype the components using 3D printing.