XD Thermal has engineered a new battery cooling architecture for a European electric bus platform. The system features liquid-cooled battery housings with stamped cover plates, allowing for heat dissipation from both sides of the modules. Each module has a capacity of 35.3 kWh.
The design integrates thermal management components directly into the housing structure. According to the company, this approach reduces the total number of cooling components by approximately 25 percent and eliminates several assembly steps. The system uses multiple thermal interfaces to improve heat distribution.
To ensure system integrity, XD Thermal implemented air and helium leak testing protocols. The company also developed specialized masking and suspension processes to apply insulating and thermal barrier coatings to complex geometries. The design reached series production readiness in about two months.
The architecture is designed to be adaptable to various vehicle platforms and battery capacities without requiring a full redesign. Since early 2025, XD Thermal has expanded its production capacity for large-format cooling components to support additional electric bus and heavy-duty vehicle projects.