Machining and Projects

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Accumulator Battery Segment Casings

Waterjetted the various panels for the segments meant to hold our HV battery packs then assembled the casing.

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High Voltage Disconnect (HVD)

Designing tabs to be welded onto the car where the HVD would be mounted

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AIRs Insulation Caps

Fixing and 3D printing a protective covering for the AIRs.

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Busbar Covers

Designing and prototyping covers for the busbars on the battery packs. This is to cover the copper portions of the segments for safety reasons. They were prototyped out of TPU and tested on the assembled segments.

The initial idea had separate covers per copper section. The covers would have a component that wraps around the copper and a “lid” piece that covers the copper and bolts. This lid is removable for access as needed.

Soon the efficient idea became converting the singular busbar cover into one design made up of multiple of them to encompass the entire battery segment. This whole piece could be removable for access to the bolts underneath.