XD Thermal Technology Enhances Industrial Cooling Solutions for Electric Vehicle Battery Packs

XD Thermal Technology, a prominent thermal management manufacturer based in Suzhou, China, has recently made significant advancements in its side-cooling solutions specifically designed for cylindrical Cell-to-Pack (C2P) battery systems. This innovation comes at a time when the electric vehicle (EV) market is experiencing rapid growth, increasing the demand for efficient battery cooling technologies.

Why Side-Cooling Matters in High-Capacity Battery Packs

As electric vehicles transition towards faster charging capabilities, managing heat accumulation during high-current operations has become a pressing challenge. The company’s innovative side-cooling concept addresses this issue by introducing serpentine cooling tubes along the cell sidewalls. This method substantially increases the effective contact area for heat dissipation, compared to traditional bottom cooling plates. The enhanced vertical contact surfaces are crucial in mitigating heat gradients that usually occur within the Z-axial direction, thereby enabling each battery cell to maintain a balanced temperature range. In turn, this balance is a vital factor for prolonging the lifespan of lithium-ion batteries.

Advanced Features and Production Capabilities

XD Thermal has developed a family of side-cooled modules and battery packs, built on strong structural integrity and rigorous quality assurance protocols. The cooling tubes are meticulously designed to align with the cylindrical cell layouts, affording flexibility for integration with various manifolds, brackets, and piping systems. This thoughtful design strategy ensures predictable heat transfer performance from the prototyping phase all the way through to mass production.

"Platformized design reduces development costs and timelines while supporting agile processes for our clients," stated Guo, a technical engineer at XD Thermal. He further emphasized that the company's proven solutions regarding pipeline connections, electrical insulation, and geometric combinations have proven instrumental in streamlining the side-cooling battery development process for numerous clients.

High-Volume Production and Industrialization

In 2024, XD Thermal ramped up its production capabilities by launching high-volume serpentine-tube lines, which boast an impressive daily output of 30,000 units. This facility combines advanced automated processes for forming, welding, and cleaning each component, supplemented by 100% leak testing to secure quality control. "Moving towards industrialization is as critical as the product development phase," shared Sun, the Head of Manufacturing Engineering at XD Thermal. "Our scalable production system, complete with a verified development roadmap and Standard Operating Procedures (SOP), enables us to efficiently prepare production lines and tooling six to eight weeks ahead of Pre-Production Approval Process (PPAP)."

Recognition and Future Outlook

XD Thermal’s industrialization capabilities and delivery performance have not gone unnoticed, as demonstrated by receiving recognition from system-level customers. In November 2025, the globally recognized automotive supplier OP Mobility appointed XD Thermal as its go-to supplier for thermal management components, thus highlighting the company’s burgeoning reputation in the automotive supply chain.

With the increasing prevalence of cylindrical C2P battery packs in electric vehicles and other applications, XD Thermal is well-positioned to capitalize on the rising need for side-cooling solutions. As the company continues to expand its production capacity and automation abilities, it aims to meet the growing demands of the EV market efficiently and effectively.

Photo Source: XD Thermal Structure