Featuring Ultrasonic Welding
New ultrasonically-welded interconnects reduce pack maintenance by 100%, with a tested electrical resistance of <1mOhm and >100N shear and peel force rating.
Background
In 2024, I pioneered the first pouch-cell battery pack to power a Carnegie Mellon Racing Formula SAE vehicle. For 2025, that architecture was improved, in almost every way. Sweeping mass and volume reductions make this our lightest battery pack ever.
— PROJECT NAME —
EV Pouch Cell Battery Module Gen 2
— APPLICATION —
CMR "25e" FSAE EV Racecar
— ACHIEVEMENTS—
FSAE Michigan 22km Endurance
3rd Place Design Award (Total Vehicle)
General Specs:
Mass – 8.8 lbs
Cost – $80/module (excluding cells)
Cell – COSMX CA95B0D0HD 13Ah x14
Voltage at 100% SOC – 60V
Module Configuration – 14s1p
Full Pack Specs (x10 Modules):
Voltage at 100% SOC – 600V
Pack Configuration – 140s1p
