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Day 2: Mahle Powertrain showcases new battery facility
Mahle
Mahle Powertrain is promoting its new battery facility in Stuttgart at Automotive Testing Expo Europe this year. This event offers an ideal platform to introduce the facility to a wide array of high-profile customers and technology partners in the region, according to the company.
The Stuttgart battery development center, located at Mahle's existing site in the Bad Cannstatt area, complements the company's new battery facility in Northampton, UK.
Together, these two centers form the backbone of Mahle’s comprehensive battery development process. They provide extensive support to customers, covering every stage from concept design, modeling and simulation, prototype and small batch assembly of modules to environmental testing and detailed validation of complete battery packs.
Simon Reader, director of engineering at Mahle Powertrain, said, "Automotive Testing Expo in Stuttgart provides the ideal opportunity to showcase our new, state-of-the-art battery facility to the many high-profile customers and technology partners in this region. These two new centers represent the central pillar of our comprehensive battery development process, supporting our customers through every step."
The Stuttgart facility has two climatic chambers capable of testing complete battery packs rated up to 550 kW, 1200V and 2000A. It can simulate extreme environments with temperatures ranging from -40°C to +90°C and humidity levels between 10% and 95%. These capabilities enable full evaluation of battery thermal management systems through simulated driving and charging cycles. The facility also includes a prototype workshop for assembling small batch volumes of modules and packs, featuring specialized equipment like a dual-robot laser welding system to ensure the accuracy and repeatability of cell tab and housing welds. Additionally, dedicated cell testing and characterization chambers are available.
Key projects currently underway at the Stuttgart facility include battery pack optimization for customers and internal projects, enhancing test procedures for battery performance development, conducting cell characterization tests to expand Mahle’s database, and supporting the parent company in optimizing systems for immersion-cooled battery technology. The team is also refining the conditions and parameters of the robot laser welding process for optimized cell tab welding.
Visitors can learn more about Mahle Powertrain’s comprehensive battery development process at Booth 1250.
Click here to register for your free expo pass.