Design and Manufacturing of a High-Performance Battery Module for an Electric Racing Vehicle

This paper presents the design and development of a high-performance lithium-polymer battery module for a Formula Student electric racecar. The goal was to reduce weight, improve manufacturability, and enhance integration compared to the previous generation. A 14s2p configuration was chosen based on energy and power requirements, with pouch cells selected for their high power density and favorable packaging characteristics. The mechanical layout, electrical interconnections, and casing design were optimized with support from benchmarking of other teams. Manufacturing was carried out using 3D-printed flame-retardant parts and laser welding of cell tabs. The final system was successfully integrated into the target vehicle, confirming its proper functionality.