How continuous development can accelerate project timelines and optimize production through effective knowledge sharing
The automotive industry is undergoing significant change as hybrid and electric vehicles rapidly evolve. Instead of relying on Tier 1 supply partners for the manufacture and supply of systems and modules, OEMs are increasingly bringing development and manufacture in-house. This is particularly true for high-value systems like batteries, power electronics (including inverters, on-board chargers, and DC-DC converters), and electric motors – a strategy that aims to drive innovation and strengthen competitiveness. Consequently, OEMs are working more directly with suppliers that have traditionally operated at the Tier 2 level, reshaping the supply chain.
Accelerating innovation through collaboration
As OEMs assume greater responsibility for system development, demand for rapid project execution and efficient scaling has never been higher. Engineering teams at leading OEMs, such as those in Germany, bring deep technical expertise and a strong tradition of quality to every project. However, the pace of technological change and the increasing complexity of electrification can create resource challenges, especially when speed-to-market is critical.
This is where collaborative partnerships become invaluable. By working closely with external experts, OEMs can leverage additional resources and specialized knowledge in design for manufacturability (DFM), materials science, and high-volume production. This support enables engineering teams to accelerate project delivery, optimize costs, and avoid resource overload, without compromising the high standards of quality and innovation for which they are renowned.
Leveraging global knowledge sharing
ENNOVI’s unique position as a global player allows it to collaborate with OEMs across different regions, including both established leaders and fast-moving innovators. For example, while Chinese OEMs are recognized for their speed and agility, German OEMs are celebrated for their engineering excellence and quality. This broad perspective enables the company to share best practices and insights gained from a diverse range of projects, helping OEMs bridge the gap in speed of execution while staying at the forefront of technology development.
To illustrate how collaborative innovation can accelerate project timelines and optimize production, let’s look at two recent examples:
New Sealing Approach to Busbar Interfaces
Busbars are essential for connecting electrical motor systems, inverters, and oil pumps. When a reliable seal is needed between coolant and dry electrical connections, traditional methods like potting or rubber O-rings can introduce complexity and potential failure points. ENNOVI has developed two advanced sealing approaches that integrate seamlessly with the injection molding process.
The double-walled shrink tubing method uses an inner adhesive layer that bonds to the metal busbar during molding, while the outer polyolefin layer integrates with the molded plastic to form a robust seal (Figure 1).
This process is integrated directly into the assembly line, reducing processing time and labor costs.
For more challenging applications, adhesive tape can be applied efficiently with automated equipment, providing excellent adhesion and resilience throughout the molding process.
Both methods eliminate post-processing steps, enabling OEMs to accelerate production and reduce costs while maintaining reliability.
Adhesive-free lamination for battery systems
Battery platforms are complex and varied. OEMs can select either cylindrical, prismatic or pouch cell structures. At the same time, battery architectures are evolving from multiple-battery modules to larger cell-to-pack and cell-to-chassis designs. A cell contacting system (CCS) collects current from each cell and transports it to the busbars and the external circuit.
Historically, CCS assembly on battery cells has relied on molded plastic trays and foam. While effective for positioning the cells and current collectors, these methods introduce unnecessary weight and complexity, especially as module sizes increase.
ENNOVI’s hot and cold lamination processes, and more recently, an adhesive-free lamination technique, offer OEMs a streamlined solution (Figure 2).
Compared with hot lamination, the adhesive-free lamination process enables OEMs to halve insulation material costs, reduce energy consumption by over 95%, and accelerate processing time by 80%.
Enabling the future of automotive innovation
As the automotive industry continues its journey toward electrification, OEMs are seizing new opportunities to innovate and lead. By partnering with ENNOVI, OEM engineering teams can access global expertise, accelerate project timelines, and optimize production costs, without compromising on quality or innovation. The company’s advanced busbar sealing and lamination technologies are just two examples of how collaborative knowledge sharing and continuous process improvement can help OEMs deliver the next generation of hybrid and electric vehicles efficiently, reliably, and competitively.
