Prismatic EV Truck Battery Design

@Mahihassi

As an Electrical Engineer and a specialist in embedded systems, I bring the expertise needed for the intricate design of your prismatic EV truck battery. With a Master’s degree in Embedded Systems, I have received extensive training in tackling projects just like yours where hardware, software, and intelligent connectivity are intricately woven together. My core mastery ranges from Microcontrollers & Embedded Systems up to like Raspberry Pi and Arduino proficiency to Product Development Workflow from prototyping to a final market-ready product your project needs. Moreover, my skills around firmware development using embedded coding & drivers like C/C++ and a strong grasp of PCB Design with RF Hardware expertise using Altium Designer, KiCad, Eagle make me well-prepared for electrical schematics, PCB Gerbers creations for cell monitoring/balancing boards much needed in this project. My team also possesses comprehensive knowledge of mechanical CAD with years of experience using SolidWorks that align with your preferred platforms.

@LiveExperts

Hello, " With over a decade of experience in electrical and mechanical engineering, we at Live Experts LLC, have consolidated a profound understanding of large-format lithium packs, thermal management, and regulatory compliance – the essential qualities for delivering an optimized battery module for your electric truck. Our proficiency in 3D modeling, CAD/CAM, Electrical Engineering, Electronics, Manufacturing Design, Mechanical Engineering, Thermal Analysis make us well-equipped to provide you with comprehensive and efficient solutions for your project. Moreover, our usage of advanced tools like SolidWorks and OnShape for CAD, ANSYS Icepak/Fluent or COMSOL for thermal-fluid modelling ensures accurate simulations which can validate design choices proactively. We understand that detailed electrical schematics and PCB Gerber files, thorough busbar drawings with current-carrying and thermal analysis, full 3-D CAD assembly with cooling plates+enclosure+service disconnect+sealing strategy along with relevant electro-thermal simulation reports will form the crux of your project. To comply with ISO standards, UL standards (notably UL 2580), and ECE R100 we assure you that our thorough documentation will include all necessary evidence—calculations, simulation reports, and references to the clauses addressed. Additionally, our work is anchored in delivering high-quality results tailored to our clients' specific needs. We believe that open c Thanks!

@AwaisChaudhry

As a professional electrical engineer and the founder of ZAWN Tech, a trusted software company, I have spent over a decade crafting reliable, production-ready solutions for complex projects like yours. I'm well-versed in cutting-edge technologies such as Altium Designer, which you have referenced, and I'm equally comfortable with others that may be suitable to meet your design objectives. What sets me apart is my proven ability to deliver not just on technical aspects but also on the compliance front—particularly relevant in your case given ISO and UL standards. In terms of hardware & IoT, my skills with Arduino, Raspberry Pi, and MATLAB mean that I understand the workings of physical systems and can integrate them with the digital effectively. Furthermore, having delivered projects where robust thermal management was key (such as computer vision systems), I believe my expertise in thermal analysis can be a significant asset for your fast-charge operation requirement. Trust is crucial. With over 200+ recommendations and an uncompromising commitment to clear communication, I assure you that your project will receive the attention it deserves throughout its lifecycle. For instance, while delivering the detailed busbar drawings that you demand, I'll conduct thorough current-carrying and thermal analysis so that your truck battery doesn't simply satisfy the requirements but performs optimally. Let's discuss how we can bring your prismatic EV truck battery design to life!

@markoa7

Hi there, I’ve reviewed your prismatic EV truck battery concept and I’m confident I can translate it into a validated, production-ready design. I’ll approach this with a tightly integrated electrical and mechanical workflow: PCB-enabled cell monitoring directly on the tabs, optimized 500 A busbar paths, and a robust cooling strategy aligned with ISO, UL 2580, and ECE R100 requirements. The deliverables will cover electrical schematics and PCB Gerbers, detailed busbar drawings with thermal analysis, a full 3-D CAD assembly (STEP + native), and an electro-thermal simulation report. I’ll provide a complete BOM and manufacturing notes suitable for RFQ, plus traceable evidence for all standards. What are your preferred tolerances for busbar contact resistance and ISO/UL documentation milestones to align the validation plan with your production timeline? Best regards, Marko Aleksic

@hayteekeys

Hi, KINDLY READ THROUGH MY PROPOSAL THIS IS WHAT I WILL DO - Deliver full electrical schematics/PCB Gerbers (Altium) for cell monitoring/balancing, busbar drawings w/ current/thermal analysis (ANSYS). - Create 3D CAD assembly (OnShape STEP/native): cells, cooling plates, enclosure, disconnect, sealing – optimize density/serviceability. - Run electro-thermal sims (COMSOL): <8°C rise @2C charge, <1% V-drop @500A, report scenarios. - Ensure ISO/UL2580/ECE R100 compliance w/ evidence, BOM/manufacturing notes for RFQ. RELEVANT PROJECTS - 2025: 600V Li-ion pack for e-bus (prismatic cells, busbars >800A) – UL2580 certified, sim-validated 1.5C charge. - 2024: Truck battery module retrofit – OnShape CAD, COMSOL thermal, production-ready w/ zero compliance issues. QUESTIONS - Cell specs (format, capacity, count for 400–800V)? - Preferred tools (OnShape ok, or SolidWorks)? - Cooling method (liquid/air)? - Timeline for V1 prototype files? I am Battery pack expert (10+ yrs EV heavy-duty). I am Ready to start immediately, with full package in about 10 days.

@kingch91

Greetings I have read and understood your requirements I can deliver you the required schematics and PCB design with BOM as per the acceptance criteria. Let's connect through the chat window to discuss and start working on it.

@Ryan15222

Hi, I am excited to submit my proposal for engineering your next-generation heavy-duty truck battery module. I specialize in high-voltage lithium-ion pack architecture, busbar design, electro-thermal validation, and compliance-driven development for automotive applications. For CAD and full assembly modelling, I work primarily in SolidWorks and Onshape, delivering production-ready STEP and native files including enclosure, cooling plates, sealing strategy, service disconnect, and structural reinforcement. Thermal and CFD simulations are performed using ANSYS Icepak and ANSYS Fluent, validating steady-state and 2C fast-charge scenarios with <8 °C temperature rise. Electrical and busbar optimization (500 A continuous, >1000 A peak) includes resistance, voltage drop (<1%), and Joule heating analysis with copper/aluminium trade-off studies. Monitoring and balancing PCBs are designed in Altium Designer, with Gerbers, stack-up control, creepage/clearance compliance, and tab-mounted integration for prismatic cells. All documentation will reference ISO requirements, UL 2580, and ECE R100, with clause-level traceability and supporting calculations. Deliverables include schematics, Gerbers, validated busbar drawings, electro-thermal reports, full 3-D assembly, and RFQ-ready BOM with manufacturing notes. My approach balances energy density, serviceability, and long-haul durability while ensuring regulatory readiness from day one. Kind regards,

@miskinarati

Hi there, I would be happy to assist with the prismatic EV truck battery module design. With strong experience in mechanical design, CAD modeling, and electro-thermal simulation, I can support development of a robust and manufacturable battery pack structure aligned with performance targets. Approach: Develop detailed 3D CAD assembly of enclosure, cooling plates, and structural components Design busbar layout considering current carrying capacity and thermal behavior Perform electro-thermal simulations to evaluate temperature rise and fast charge conditions Validate mechanical integration for serviceability and packaging constraints Provide engineering calculations and simulation documentation Deliverables: Full 3D CAD assembly with manufacturing-ready files Busbar design drawings with analysis results Electro-thermal simulation report Design documentation and engineering notes Timeline: To be determined after discussing project scope. Budget: Open to negotiation based on complexity. Looking forward to collaborating on this project. Let’s connect to discuss further. Best regards, Arati M.

@hayat38402

Hi, how are you doing? I went through your project description and I can help you in your project. your project requirements perfectly match my expertise. We are a team of Expert Mechanical design Engineers, we have successfully completed 1000+ Projects for multiple regular clients from OMAN, UK, USA, Australia, Canada, France, Germany, Lebanon and many other countries. We are providing our services in following areas:  FEA analysis  CFD analysis  Thermal analysis  Structural analysis  HVAC and Heat load calculation We are proficient in using following software’s:  AUTOCAD  SOLIDWORKS  ABAQUS  ANSYS Fluent  MATLAB/SIMULINK  COMSOL Multiphysics  CATIA  FUSION360 We have good command over REPORT WRITING, we can show you many samples of our previous reports. We can discuss further details in the message box.

@umaranimators

As a highly experienced 3D artist and CAD/CAM specialist with over seven years in the industry, I believe I am the optimal choice for realizing your Prismatic EV Truck Battery Design project. Coupled with my expertise in 3D modelling using platforms like SolidWorks, OnShape (preferred), as well as other necessary tools such as ANSYS Icepak/Fluent and Altium Designer, I am well-prepared to deliver exceptional results that meet your exact specifications. Understanding the stringent ISO, UL, and ECE R100 standards and their relevance to your project is something I take very seriously. My capabilities in computational analysis and thermal management will ensure effective electro-thermal simulations and precise design simulations using software like COMSOL or its equivalent. Moreover, my continuous track of producing detailed documentation supported by comprehensible references will give you peace of mind during the compliance process. Lastly, my focus on quality aligns perfectly with the demands of the project. I am dedicated to developing a battery pack design that guarantees high energy density without compromising serviceability while optimizing calendar and cycle life for long-haul duty cycles. Together, we can build a battery that withstands heavy electric truck demands. Let's get started!

@juliantobahari

Hi, I'm Juli a 3D design specialist. I've read your job description and I'm confident I can help. I have solid experience with SolidWorks, Fusion 360, AutoCAD, and rendering tools like KeyShot and Twinmotion. I'm committed to precision, fast delivery, and clear communication. Let me know if you'd like to move forward! Best regards, Juli

@dnx38

I am a Mechatronics Engineer with specialized experience in high-power battery systems, industrial control PCBs, and thermal management for demanding automotive applications. I've designed BMS architectures for large-format lithium cells, including cell-tab-mounted monitoring boards with robust current sensing, balancing circuits, and high-current busbar routing capable of handling 500A+ continuous loads with verified thermal performance. My workflow integrates SolidWorks CAD modeling with ANSYS thermal-fluid simulations to validate temperature distribution under fast-charge scenarios, ensuring compliance with ISO, UL 2580, and ECE R100 standards through documented calculations and design justifications. I deliver production-ready electrical schematics, PCB Gerbers, 3D STEP assemblies (including cooling plates, enclosures, and service disconnects), busbar drawings with current-carrying analysis, and complete manufacturing documentation for RFQ—all validated to meet your <8°C temperature rise and <1% voltage drop criteria at peak loads for long-haul electric truck duty cycles.

@electronicsdone

Best Prismatic EV Truck Battery PCB Design Expert ⭐⭐⭐⭐⭐ Hi, Thank you for posting your project, “Prismatic EV Truck Battery Design.” I’ve reviewed your requirements and can help you turn your next-generation heavy-duty lithium-ion battery concept into a validated, production-ready design, including high-current busbars, integrated monitoring PCBs, full 3-D mechanical assemblies, and electro-thermal simulations. I bring 11+ years of experience in high-voltage battery pack design, large-format lithium modules, thermal management, PCB layout for cell monitoring, and compliance with ISO, UL, and ECE standards. ✅ How I’ll Help You Succeed 1. Design prismatic cell modules with integrated PCBs and high-current busbars for 500–1 000 A operation. 2. Deliver full assemblies, electro-thermal simulation reports, and optimized cooling strategies. 3. Provide complete electrical schematics, PCB Gerbers, BOM, and manufacturing documentation ready for prototype and production. ✅ Before I start, one quick question: Do you want me to propose optimized thermal management strategies along with the electrical layout or focus first on the electrical and PCB design while following your mechanical concept? If you share that, we can align quickly and move forward. Best regards, Prat PCB Must Innovations

@borisdeveloper71

Hi, there. Your vision for a high-performance prismatic EV truck battery is exactly the type of challenge I specialize in. With extensive experience designing large-format lithium-ion packs for commercial vehicles, I am well-versed in integrating robust monitoring electronics, designing high-current busbars for demanding duty cycles, and optimizing thermal management for fast charging. I fully understand the importance of achieving high energy density while maintaining serviceability, rigorous compliance with ISO, UL 2580, and ECE R100 standards, and delivering thorough documentation including simulation evidence and clause-by-clause compliance. My approach involves starting with a detailed requirements capture and architecture proposal, then developing the electrical schematics and Altium PCB layouts for cell-level monitoring, followed by 3D CAD modeling in SolidWorks—including cooling, sealing, and service disconnect features. For the critical electro-thermal analysis, I leverage ANSYS Icepak to validate cooling effectiveness and ensure temperature rise remains below your 8 °C target at 2C charge rates. All design stages are supported by comprehensive simulation reports, manufacturing-ready files, and a clear bill of materials—ensuring a smooth transition to prototyping and regulatory scrutiny. I am confident that my track record in heavy-duty EV battery design, hands-on experience with prismatic cell architectures, and commitment to compliance can help bring your next-generation battery module from concept to production-ready reality. Best regards Boris

@tetianam8

As a seasoned electronic engineer with expertise in the design and production of complex PCB layouts and embedded systems, I believe my skills align perfectly with your project's requirements. My proficiency with PCB design software including Altium Designer, KiCAD, and Eagle combined with my knowledge of high-current routing and battery management systems will prove invaluable in turning your battery concept into a validated, production-ready design. With over 15 years of experience, I have a deep understanding of regulatory standards and compliances that would be adhered to for this project. My track record in satisfying industry standards such as ISO and UL is well-documented. This will ensure that alongside the electrical layout, you will receive a full 3-D mechanical model, electro-thermal simulations, and design files ready for prototype manufacture - all in accordance to your reference standards. Moreover, given my mastery of various programming languages including C/C++ and Python and my familiarity with communication protocols such as I2C, SPI, UART, CAN, Ethernet - key skills needed for developing an efficient battery module - I am confident that my collaboration with you will bring your vision to fruition. I invite you to leverage on my commitment to quality and my knack for delivering projects with precision and efficiency.

@trm66614

Hi there, Good morning I am Talha. I have read you project details i saw you need help with CAD/CAM, Manufacturing Design, CATIA, Electrical Engineering, 3D Modelling, Electronics, Thermal Analysis, Mechanical Engineering and Altium Designer I am excited to submit my proposal for your project, which focuses on a comprehensive project plan. To begin, we will thoroughly understand your project's objectives and requirements, ensuring alignment on scope and goals. We will provide a clear and realistic project timeline with manageable milestones to ensure timely completion Please note that the initial bid is an estimate, and the final quote will be provided after a thorough discussion of the project requirements or upon reviewing any detailed documentation you can share. Could you please share any available detailed documentation? I'm also open to further discussions to explore specific aspects of the project. Thanks Regards. Talha Ramzan

@engrhasan01

Hi,I can support the end-to-end engineering of your 400–800 V heavy-duty EV battery module, covering electrical architecture, high-current interconnect design, integrated cell-monitoring PCBs, 3D mechanical modelling, and electro-thermal validation aligned with UL 2580, ISO, and ECE R100 requirements. My approach will focus on safe high-voltage layout, creepage/clearance control, robust busbar design (500 A continuous / >1 000 A peak), low-resistance interconnects to maintain <1% voltage drop, and thermal optimization to keep cell ΔT <8 °C during 2C fast charge. I can deliver Altium PCB designs, detailed busbar current-density and thermal analysis, full STEP + native CAD assemblies (SolidWorks/OnShape) including cooling plates and sealing strategy, plus CFD-based simulation reports (ANSYS/COMSOL equivalent) with documented compliance references. The final package will be RFQ-ready with calculation sheets, BOM, and manufacturing notes. This is a complex, safety-critical system, and I’m comfortable structuring the work in milestones (architecture → thermal model → PCB → compliance mapping → final validation) to ensure production readiness. Let’s discuss cell specs, cooling method (liquid/plate), and target capacity so we can define the baseline configuration.

@ShahzaibxArt

Hello, I’m a professional CAD designer with strong experience in Fusion 360, specializing in high-quality 3D models, 3D printing–ready designs, and precise technical/manufacturing drawings. I ensure: • Clean and accurate modeling • Proper tolerances for manufacturing & 3D printing • Fully detailed technical drawings (dimensions, sections, tolerances) • Fast delivery with clear communication I’ve worked on multiple CAD projects and always focus on accuracy, practicality, and client satisfaction. I’d be happy to discuss your project requirements and deliver exactly what you need. Best regards, Shahzaib

@susiek0125

Hi, there, Thank you for outlining such a comprehensive and forward-thinking project. As an experienced engineer with a strong background in lithium-ion battery systems, thermal management, and regulatory compliance, I am excited by the opportunity to help realise your next-generation prismatic EV truck battery. ✅ Understanding & Approach You require a production-ready design for a high-voltage (400–800 V) battery module utilising large-format prismatic cells, with integrated cell monitoring, robust busbars (500 A continuous, >1 000 A peak), and advanced thermal management to support 2 C fast charging. The solution must meet stringent ISO, UL 2580, and ECE R100 standards, with documentation and simulation evidence covering every compliance aspect. ✅ Technical Implementation - **Electrical & PCB:** I will design the monitoring/balancing boards in Altium Designer, ensuring safe, low-resistance integration on cell tabs. - **Mechanical & Thermal:** I will create the pack’s 3D model in SolidWorks, including serviceable enclosures, cooling plates, disconnects, and sealing. CFD simulations using ANSYS Icepak/Fluent will optimise the thermal path, validating <8°C cell rise at peak load and minimal voltage drop. - **Busbars:** Detailed copper/aluminium busbar layouts will be developed with both current-carrying and thermal analysis, supported by precise drawings. - **Compliance:** Each deliverable will be cross-referenced with relevant clauses from ISO/UL/ECE standards, and I will provide calculation and simulation reports as evidence. ✅ Deliverables - Schematic, Gerber, and BOM files for monitoring PCBs - CAD files (STEP/native), manufacturing notes, and full assembly for prototyping - Electro-thermal simulation report (steady-state & fast charge) - Documentation meeting all acceptance and compliance criteria I can start immediately and am confident my expertise will deliver a robust, serviceable, and compliant battery pack design for your heavy-duty EV application. I am looking forward to working with you. Best Regards Susie Kalson