Form Energy · Pack architecture

Iron-air pack architecture

Three generations of pack architecture, UL-aligned, at a 30% cost reduction.

3Generations
30%Cost reduction
4Enclosures per system
ULAligned

Scope

Led the ME and EE team designing the structural, thermal and high-voltage components — and every harness in the system — across three generations of pack architecture.

Full system quad pack in the field.
Full system quad pack in the field.

System layout

Four battery enclosures per system pair with a DCDC combiner, configured differently for charge and discharge paths. The architecture had to hold up structurally, thermally and electrically at the same time — and then be manufacturable.

Enclosures at the build site.
Enclosures at the build site.

Deployment

Systems in the field are where architecture decisions are judged. Installation access, serviceability and thermal behaviour under real ambient conditions all fed back into the next generation.

Deployed site.
Deployed site.