Tesla Model S module
Each of the 444 cells has its own thin wire bond to the busbar. If a cell fails, its bond burns open and the rest carry on.
Battery benchmark studies
Two production battery packs, studied part by part.
A Tesla Model S module and an Ather 450 pack, studied from photos and a real pack seen up close, then modeled the way each part is actually made. Neither was taken apart.
- Deliverables
- Two complete 3D models, with exploded views.
Laid out layer by layer
Exploded in the order it goes together.
- 1Top busbar plates
- 2Sense ribbon
- 3Top carrier
- 4Coolant ribbon
- 5Side cover
- 6Bottom carrier
- 7Bottom busbar plate
- 8Cells
- 9Monitoring board
Ather 450
One aluminum die casting is the structure, seal and heat sink. Phase-change material and fins keep it cool, with no pumps or fans.
Inside the casting
A circuit board on top doubles as the busbar, so there are no welded strips or loose wires.
- 1Cast lid
- 2Port plate, power and signal
- 3PCB busbar
- 4Cells set in holders
- 5Battery management board
- 6Cast base with fins
