Battery Thermal Management
Battery Liquid Cold Plate Design & Manufacturing
We design and manufacture custom battery liquid cold plates that are engineered for real-world production. If you are an engineering-driven OEM with a thermal target, a drawing, or a new battery program, we turn your requirements into tested prototypes and repeatable volume builds.
As a thermal solution partner since 2014, we integrate design, DFM, machining, joining and testing under one supply chain. You get a manufacturable cold plate that meets thermal performance, pressure integrity and cost targets.
Custom battery cold plate — prototype to mass production
What you get when you work with us
A single accountable partner from thermal concept through validated production.
A manufacturable battery cold plate
We review your design for DFM, select the right manufacturing method, and prevent downstream redesigns and tooling changes.
Validated thermal and pressure performance
Thermal resistance testing and leakage/pressure tests help your team enter system validation with confidence.
Faster program cycles
Integrated prototyping, machining and joining let you iterate earlier, lock the design sooner and stay on schedule.
Cost matched to volume
We choose vacuum brazing, friction stir welding or embedded tube processes according to geometry, volume and target cost.
One accountable partner
Thermal design, mechanical design, machining, joining, finishing and inspection are consolidated to reduce handoffs and schedule risk.
Documentation that transfers to production
You receive process recommendations, inspection plans and test reports that support repeatable volume builds.
Manufacturing technologies for battery liquid cold plates
We select the method based on your heat load, flow rate, channel geometry, pressure requirement and budget.
Vacuum-brazed aluminum cold plates
Microchannels or serpentine channels for high heat flux; engineered for operating pressures above 10 bar depending on structure.
Friction stir welded (FSW) cold plates
Seam-free, high-integrity joints for large-format plates or multi-piece assemblies.
Embedded copper tube plates
Cost-effective cooling with exposed, half-buried, full-buried or sandwiched-tube layouts.
CNC-machined flow channels
Custom geometries with controlled tolerances, combined with brazing or sealing methods as required.
Custom microchannel structures
Designed to balance thermal resistance, pressure drop and pump power for your application.
Finishing options: Anodizing, hard anodizing, nickel plating, passivation, sandblasting, polishing and cleaning.
Engineering support before manufacturing
A battery cold plate's performance depends on heat load, contact area, coolant type and flow, channel geometry, pressure drop, materials, interface flatness, mounting, and environment. We align these variables with manufacturability.
Talk to an Engineer- Thermal solution development and structure design
- Mechanical design and DFM review
- Material and process selection (aluminum or copper; brazing, FSW, embedded tube)
- Thermal simulation support on request
- Prototype development and product optimization
- Thermal resistance and pressure/leakage testing
- Dimensional and quality inspection
We work with AutoCAD, SolidWorks and Creo. Send a drawing for build-to-print manufacturing or provide your thermal requirements for engineering evaluation.
How faster manufacturing shortens your battery program
Early DFM feedback reduces redesign loops
We flag channel geometries, wall thicknesses and joint details that will not scale, so you avoid late-stage changes.
Integrated prototyping accelerates validation
Testable prototypes with production-representative channels and joints enable earlier thermal and pressure verification.
Single supplier scheduling reduces idle time
Machining, joining, finishing and inspection run within one system, cutting waiting time between vendors.
Pilot-ready documentation avoids transfer delays
Inspection and test plans are prepared with production in mind, so pilot runs start sooner with fewer surprises.
Technical parameters for battery liquid cold plates
| Parameter | Capability |
|---|---|
| Main materials | Aluminum 1060 / 6061 / 6063; Copper C1100 |
| Manufacturing methods | Vacuum brazing, Friction stir welding (FSW), Embedded/exposed/half/full-buried tube, CNC-machined channels |
| Channel geometry | Serpentine, parallel, microchannel, custom per application |
| Operating pressure | Designed per application; aluminum vacuum-brazed structures engineered for >10 bar depending on design |
| Coolant compatibility | Water-glycol, deionized water, dielectric fluids (as specified) |
| Joint integrity | Vacuum-brazed joints or FSW seams selected for required pressure and leak performance |
| Plate thickness | Defined by design; CNC machining capability supports tight tolerances |
| Machining precision | ±0.002–±0.008 mm machine capability (feature-level) |
| Flatness and surface | Controlled per spec; anodizing / hard anodizing / nickel plating available |
| Fittings & ports | Barbed, threaded or quick-connect; location and size per drawing |
| Testing & inspection | Leakage testing, pressure testing, thermal performance testing, flow-channel inspection, dimensional inspection |
| Documentation | DFM report, process recommendation, inspection plan and test results upon request |
| Development model | Prototype → Validation → Pilot Run → Mass Production |
Note: Final specifications depend on geometry, material, channel design and test requirements. We match the process to your application and production plan.
Production capacity and equipment
Scale your program with proven capacity and in-house inspection for battery cold plates and thermal assemblies.
Request Capacity Review30,000
Liquid cold plates / month
200,000
Aluminum heat sinks / month
150,000
Soldered aluminum/copper heat sinks / month
50,000
Skived fin heat sinks / month
300,000
Precision machined parts / month
Representative equipment & inspection
- CNC machining centers: 50 sets
- Friction stir welding machines: 2 sets
- Stamping, soldering, skiving, tapping, cleaning and assembly lines
- CMM, 2D measurement, thermal testing and leakage testing
Typical battery pack applications we support
EV traction battery packs
Module-level cooling for electric vehicle battery systems.
Energy storage systems (ESS)
Stationary battery thermal management for grid and commercial storage.
High-power charging & DC bus
Cooling modules for fast chargers and DC power distribution.
Power electronics subassemblies
Integrated thermal management for battery-connected power electronics.
From prototype to production
Start with a simple flow-channel concept or a full assembly drawing. Our goal is the same: make your battery cold plate manufacturable, repeatable and ready for production.
Prototype
Build to evaluate thermal and pressure targets.
Validation
Confirm performance and refine manufacturability.
Pilot run
Lock process windows and inspection plans.
Mass production
Repeatable quality and schedule at volume.
What to include in your RFQ
To quote accurately and recommend the right manufacturing method, please send the details below. The more we know, the faster we can move to DFM and prototype.
Upload Your Drawing- •2D drawing and 3D CAD file (STEP/IGES/Parasolid)
- •Heat load and target thermal resistance
- •Heat source dimensions and contact area
- •Coolant type, inlet temperature and flow conditions
- •Operating pressure, test pressure and leakage test method
- •Allowable pressure drop or pump constraints
- •Available installation space and envelope
- •Mounting hole pattern and port specifications
- •Surface finish and corrosion protection requirements
- •Annual volume and build schedule
Request a quote
Send us your RFQ with drawings and requirements. We will provide DFM feedback, a recommended process, pricing options and an indicative lead time.
- • DFM feedback focused on manufacturability and repeatability
- • Recommended process (vacuum brazing, FSW, embedded tube) with rationale
- • Pricing options matched to prototype, pilot and mass production
- • Indicative lead time and test/inspection plan