Vaulta – Simply Superior Battery Casing Technology

  • 2022

  • Engineering

Commissioned By:

Dominic Spooner

Designed In:


Vaulta has developed a patented combination of smart design and materials that creates a lighter, cheaper and thermally superior battery case, and eliminates the need for complex assembly. With no welding, cells can be reused and reconfigured as needed. Perfect for stationary storage projects, electric vehicles, niche products and more.

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  • Battery cell technology has evolved rapidly in recent years – but battery case technology hasn’t been keeping up. Today’s battery cases are unnecessarily complicated and costly, with too many parts and too much machinery required to assemble them. They add too much size and weight to batteries, which affects performance, and are prone to ongoing maintenance issues. They also need to be welded to the battery cells, which is a nightmare for battery recycling and re-use. Only around 2-5% of lithium-ion batteries are recycled, and the way we case batteries is a large reason for that.

  • Using advanced composite materials and a smart, streamlined design, Vaulta’s battery casing condenses multiple functions into fewer parts, with no welding required. Vaulta’s simple design means modules can be easily assembled and disassembled, and cells can be reused and recycled, reducing waste and, crucially, giving batteries a second life. Vaulta's patented materials makes its casing thermally superior, and 10-15% lighter than current battery cases. Vaulta’s battery casing works for all cell type, are easier to maintain and assemble in the field, and can be easily configured to suit different needs.

  • Vaulta's design reduces cost to market, build cost by approximately 10%, and minimizes design iterations. By using a weld-free design, batteries can be assembled either manually or via automation, meaning local assembly, wherever that may be is better enabled. By being able to easily disassemble battery modules, Vaulta's design works to eliminate battery waste and enhances the recycling process and purity by allowing recyclers to get down to the cell level. By getting down to the cell level, cells can also be diverted form landfill and recycling and be used in second life applications 2 and 3 times over.

  • 1. Reduction in parts – for some customers by up to 40% 2. By minimizing unique design parts it minimizes tooling expenses 3. Reduction in build cost – for some customers by more than 10% 4. Liquid cooling is enabled by easy add on plates connected to the thermally conductive casing 5. The casing in most applications adds less than 5-10% of cell mass 6. cell module acts as the “cell” in a cell to pack configuration 7. Designed for forced air across terminals 8. Casing is able to withstand mobility testing and UN38.3 testing Vaulta's design flexibility means that the product pipeline, through a single module design, contains commercial energy stationary storage, residential energy storage, lead acid replacement/lifestyle and off-grid energy storage, and mobility through passenger electric vehicles. These products are all expected to be commercialized between June 2022 and June 2023.