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Low Pressure Molding (LPM) |
Injection Molding |
Potting |
Conformal Coating |
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Environmental isolation plus thermal management helps spread heat and reduce localized heating, supporting cycle life, performance consistency, and safety margin. |
Provides basic environmental isolation and electrical safety, but lacks precision and thermal control required for tightly packed or high-performance battery systems. |
Poor fit due to pressure, temperature, and safety risks when molding around live cells or assembled battery systems. |
Provides sealing and protection, but weight, thermal limitations, and slow processing make it challenging for scalable battery systems. |
Surface protection only; does not provide mechanical restraint or thermal benefits |
Battery Packs
Battery packs are constrained by a familiar set of problems: managing heat, surviving shock and vibration, keeping contaminants out, and building packs with consistent quality at scale. X2F supports solid, precise encapsulation of cells, packs, and circuitry with controlled processing conditions. This helps manufacturers build more robust packs without turning protection and structure into a multi-part assembly.
Thermal Management Built Into the Assembly
Thermal design often forces tradeoffs between performance, protection, and manufacturability. X2F supports thermally conductive materials for heat spreading, enabling pack designs that manage heat through the structure instead of relying only on add-on thermal parts and interfaces.
Structural Durability for Shock, Drop, and Vibration
Drops and vibration can drive cell movement, connector stress, and damage at tabs and interconnects. X2F’s structural encapsulation can stabilize cells and connectors, improving durability in mechanically demanding environments.
Sealing and Environmental Protection
Battery reliability is highly sensitive to contamination and ingress. X2F forms durable sealing barriers that protect against water, dust, and other contaminants as part of the molded structure, supporting more consistent environmental protection.
Controlled Processing for Cells and Tabs
Batteries and tabs can be sensitive to heat and mechanical load during encapsulation. X2F uses controlled heat and low pressure to limit processing stress on cells and interconnects while still achieving defined coverage and geometry.
Design Freedom with Defined Geometry
X2F enables defined shapes and features within the molded pack, including channeling, connector mounts, reinforcement, and strain relief. This helps integrate mechanical and protective functions directly into the pack structure.
Defect Control in Critical Regions
Voids, gaps, and material entrapment around cells and connectors can undermine both durability and sealing. X2F’s controlled flow and repack capability helps minimize voids around cells, supporting more consistent builds.
Production-Ready Repeatability
X2F is designed for repeatable cycles that support medium-to-high volume battery pack production, with consistent outcomes across builds as designs scale.
Safety-Related Feature Integration
X2F can mold defined isolators, spacing features, channels, and strain reliefs that support pack-level safety architecture. This lets manufacturers integrate isolation and protection features directly into the molded structure.