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original in design,
exceptional in performance

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INTEGRATION CASE STUDIES

cell
core
skins



Cell
Core
Skins
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cell
Core
skins
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space environment (thermal,
vacuum, vibrations, shock)
- use case boundaries definition
- user requirements collection

IOD and proven operational in space
environment
- structural battery design feasibility study
- batteries electrical and mechanical performance simulation (FEM)

proposal
- ok-to-go for production

- production and testing
- applications specific certification.

- Battery installation & integration
- after-sales assistance
- use case boundaries definition
- user requirements collection

proposal
- ok-to-go for production

- Battery installation & integration
- after-sales assistance

environment
- structural battery design feasibility study
- batteries electrical and mechanical performance simulation

- production and testing
- applications specific certification.

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QUESTIONS
what is a structural battery?
A structural battery is a radical innovation which combines load-bearing with energy storage capabilities. Like turning the walls of a house into both the foundation and the power plant. For a structural battery to function effectively, significant engineering effort is required to ensure competitive energy storage performance, mechanical robustness, and failure-resistant structures.
Why should I put a structural battery in my systems?
Structures are fundamental in mobility, ensuring product integrity, yet in electrification they remain mere deadweight. By turning structures into energy storage, you can eliminate conventional batteries that consume mass and volume, freeing space for valuable payload. The result: a more efficient, leaner, and smarter system—light-years ahead.
Does implementing structural batteries requires frames/structures re-design?
Volta Structural Batteries are shaped like common composite sandwich panels, widely used in aerospace, maritime and automotive applications. They share similar stranght and rigidity properties and the final product is build to replace your standard sandwich panels using the same attachment points/methods
Can the structural battery follow a curved profile?
Yes, the structural battery can have curved shapes, not just planar forms. The curvature limits are the same as those of sandwich panels, which have curvature radii limited by technological processes. However, by adopting special honeycomb patterns, forms with very tight curvature radii can also be achieved.
Can I drill holes in the structural battery panel?
Yes, holes can be made in the structural battery panel. However, it is important to design the position of the holes during the panel design phase to ensure they do not coincide with electrochemical cells, which would compromise the final electrochemical performance.
How do I connect the structural battery to my system?
The structural battery has mechanical interfaces that allow perfect mechanical integration with the rest of the structure, using bushings and other standard inserts according to requirements. For electrical connections, standard connectors can also be used according to system needs.
What voltages can the structural battery achieve?
Voltages up to 800V can be achieved. Within the panel surface, electrochemical cells can be connected in series and parallel according to requirements and depending on the available surface area of the structural panel. For high voltages, insulating layers in the sandwich panel skins will be necessary to ensure system safety.
What happens in case of impact/damage to the structural battery if exposed in a crash-prone area?
The structural battery has an architecture well-suited for impact absorption. However, depending on the impact risk, it is important to choose appropriate chemistry that does not pose thermal runaway risks even in cases of perforation and large deformations. Sodium-ion chemistry is an example of chemistry to adopt in such cases.
In case of contained damage, the same repair techniques used for sandwich panels can be adopted to restore the mechanical properties of the panel. The electrochemical properties will be reduced as the damaged electrochemical cells are isolated from operation. Therefore, it is important during the design phase to evaluate the impact risk of the structure to ensure a correct and reliable design.