XD Thermal Enhances Its Side-Cooling Solutions for Battery Packs

XD Thermal Technology, a leading thermal management manufacturer based in Suzhou, China, recently announced significant advancements in its side-cooling solutions aimed at cylindrical Cell-to-Pack (C2P) battery configurations. With the increased adoption of high-capacity lithium-ion battery technologies, effective thermal management has become crucial to ensure the reliability and longevity of battery systems.

The Challenge of Heat Management

As battery technology continues to evolve, especially with faster charging capabilities, managing thermal conditions during operation has become increasingly complex. In typical fast-charging scenarios, there is a significant risk of heat build-up due to high currents and voltages, which can lead to reduced battery performance and lifespan. XD Thermal addresses this critical issue with its innovative side liquid-cooling design. These systems utilize serpentine tubes strategically placed along the sides of the battery cells, which enhance the effective cooling area compared to traditional bottom-cooling designs.

This approach effectively minimizes heat gradients within the cells, ensuring that each unit remains within an optimal temperature range—a key factor in prolonging battery life.

Modular Design for Flexibility

In response to diverse customer needs, XD Thermal has developed a family of side-cooled battery modules that emphasize both robustness and quality assurance. The cooling tubes are designed to fit seamlessly with various cylindrical cell layouts, offering flexibility in conjunction with different manifolds, brackets, and pipeline configurations. This modular approach allows the company to maintain predictable heat-transfer performance from prototype stages to mass production.

Guo, a technical engineer at XD Thermal, emphasizes that “platformized design reduces development costs and time, while also supporting agile product development for our partners.” The company claims that its validated design rules and proven connection systems have successfully facilitated smooth side-cooled battery development for numerous clients.

Scalable Production Capabilities

To meet the rising demand for cooling solutions, XD Thermal has optimized its manufacturing capabilities. In 2024, the company launched high-volume production lines capable of yielding 30,000 units daily. These lines incorporate automated processes for forming, welding, cleaning, and even 100% leak testing. To ensure quality, welds undergo inspections via advanced 360-degree 3D-scan technology, verifying the completeness of weld coverage on tubes, manifolds, and all related components.

According to Sun, the Head of Manufacturing Engineering, “Ramp-up and industrialization are as important as the product development phase.” He notes that XD Thermal provides repeatable, scalable production systems bolstered by a confirmed development roadmap and standard operating procedure (SOP) schedules. Typically, production line preparations are completed 6-8 weeks prior to the initial Product Part Approval Process (PPAP).

Recognition from Industry Leaders

The industrialization and delivery capabilities of XD Thermal have not gone unnoticed in the competitive landscape of battery suppliers. In November 2025, the company was officially named a thermal-management component supplier by OP Mobility, a prominent global tier-1 automotive supplier. This recognition underscores the confidence industry leaders place in XD Thermal’s solutions, particularly as C2P battery packs gain traction in the electric vehicle (EV) sector and other applications.

As the demand for cylindrical C2P batteries continues to surge, XD Thermal is poised to capture this expanding market through its advanced offerings in side-cooling solutions. The company is set to lead with a combination of ample production capacity, high levels of automation, and a mature design platform, ensuring its vital place within the evolving landscape of thermal management in battery technology.