Powering the Next Generation of Energy Storage
As the demand for electric vehicles and residential energy-storage systems accelerates, manufacturers face growing pressure to build stronger, lighter, and safer battery packs, all while scaling production efficiently. Every joint in a battery pack matters. The way those enclosures, trays, and busbar supports are assembled directly affects thermal performance, vibration resistance, and long-term durability.
For many, that’s meant relying on threaded fasteners or welding. But as materials, performance expectations, and cleanliness standards evolve, those joining methods show their limits.
That’s where permanent forming and riveting technologies come in.
Why Traditional Methods Fall Short
Battery pack assemblies involve a mix of aluminum, coated steels, and composite materials, often paired with sensitive electronics, seals, and thermal interfaces.
Each of these introduces challenges for traditional fastening:
Welding: Generates heat that can distort thin aluminum enclosures or compromise seals. It also introduces spatter and fumes, which can be problems in clean or ESD-sensitive environments.
Threaded Fasteners: Add cost and complexity, create potential for loosening over time, and often require torque verification. They can also generate chips or debris that threaten insulation and sealing surfaces.
Adhesives: Useful in some applications but difficult to control, rework, or verify for structural integrity.
Manufacturers are finding these processes can slow production, reduce repeatability, and add rework costs, especially in high-density packs with tight tolerances and demanding safety requirements.
A Better Way to Join: Permanent Forming
Orbital and radial forming, along with impact riveting, offer a cleaner, quieter, and more consistent alternative.
These processes use precisely controlled force and motion to form metal without cutting or melting it. The result: a solid, repeatable joint with no heat, no chips, and minimal stress on surrounding materials.
Benefits for Battery Pack Manufacturing:
No Heat or Debris: Ideal for sealed or ESD-sensitive environments.
Consistent Clamp Load: Critical for maintaining pack compression and sealing integrity.
Low Noise and Vibration: Perfect for clean, quiet production environments.
Compatible with Mixed Materials: Joins aluminum, coated steels, and composites without distortion.
Easy Validation: Force and position monitoring ensure every joint meets spec.
From tray and lid fastening to busbar supports, cooling plates, and terminal connections, permanent forming supports the clean, repeatable processes battery manufacturers need to scale safely.
From Pilot to Production
Many battery manufacturers start with small pilot lines before scaling up to full production. Orbitform makes that transition seamless.
Our customers often begin with a bench-top forming or riveting system equipped with data capture and process monitoring. Once they prove out their joints, we help them scale up to semi-automated or fully automated systems without changing the fundamental joining process.
Orbitform’s in-house Solutions Lab helps customers:
Validate joints through destructive and fatigue testing
Capture force-displacement data to compare with screws or welds
Develop tooling and head geometries tuned to their specific stack-up and cycle-time requirements
This early partnership reduces risk, improves launch speed, and ensures consistent results from prototype to production.
Proven in Energy Storage Applications
Battery and EV manufacturers already use Orbitform equipment to assemble:
• Pack trays and lids (low noise, no distortion)
• Cooling plates and brackets (controlled clamp for sealing surfaces)
• Busbar and terminal supports (precise, debris-free forming)
• Enclosure hinges and brackets (strong and repeatable joints)
These processes not only improve joint integrity but also support quality traceability with integrated monitoring, SPC, and serialization options.
Partner with Orbitform for a Smarter Assembly
At Orbitform, we help manufacturers build better battery packs by providing proven, permanent joining solutions that enhance safety, reliability, and efficiency.
Whether you’re designing your first pilot line or expanding full-scale production, we can help you define, test, and implement the right joining process for your application.
Contact us to discuss your battery assembly challenges or schedule a lab feasibility test to compare forming vs. traditional joining methods.