XD THERMAL Unveils Cutting-Edge Cooling Architecture for Electric Bus Platforms in Europe
XD THERMAL has recently completed the development of a state-of-the-art dual-sided liquid cooling architecture aimed specifically at enhancing the performance of electric bus platforms in Europe. This groundbreaking system incorporates a 35.3 kWh battery, which integrates liquid-cooled casings with stamped upper plates. This design allows for efficient heat management from both sides of the battery modules, a critical aspect in ensuring optimal performance for electric vehicles.
The initial prototype of this innovative architecture was delivered in approximately six weeks, with the design reaching production readiness within just two months. This rapid development cycle demonstrates XD THERMAL's commitment to innovation in electric vehicle technology.
One of the key benefits of this new architecture is the 25% reduction in cooling-related components, achieved by integrating cooling functions directly into the battery casing. This integration simplifies several assembly steps and enhances heat distribution throughout the battery system, which is essential for prolonging the lifespan of lithium batteries.
However, the development journey encountered several challenges, particularly in the area of system-level sealing validation. This process involved thoroughly assessing multiple interfaces, seals, and sealing pathways simultaneously, rather than treating them as separate components. To address this challenge, the engineering team designed precision instruments and conducted systematic air and helium leak tests to ensure sealing integrity and to detect minor leaks before product launch.
Another notable challenge was the establishment of a reliable production process for the multifunctional coating system. The varying surfaces of the battery casings required different insulating and thermal barrier materials, rather than a uniform coating application. Accordingly, customized fastening and masking methods were developed to ensure defined coating boundaries and a consistent application across complex geometries.
Xu, the Chief Technical Officer of XD THERMAL, stated, "Once cooling is integrated into the casing, the design boundaries change. The challenge is no longer about optimizing a single cooling plate, but about ensuring that the entire structure delivers stable thermal performance while remaining feasible for manufacturability."
To facilitate this comprehensive approach, teams across thermal management, structural integrity, process engineering, quality assurance, and manufacturing have collaborated closely throughout the development phase. This synergistic effort allowed the insights gathered from prototypes to inform and enhance design and process revisions directly.
The scalable architecture developed by XD THERMAL can be adapted to various vehicle platforms, battery sizes, and capacity requirements without the need for a fundamental redesign of the cooling concept. Since early 2025, the company has expanded its thermal management operations for commercial vehicles, dedicating manufacturing resources for larger-format battery cooling components and achieving volume production by year-end. This manufacturing base now supports electric bus programs and heavy vehicles beyond the initial platform, integrating engineering, validation, and production resources into a unified workflow suitable for programs with diverse battery dimensions and structural needs.
Furthermore, XD THERMAL will actively participate in the IAA TRANSPORTATION 2026 event in Hannover this September, hosting discussions on battery integration, manufacturing capability, and the transition from prototype to series production in collaboration with industry partners. This involvement showcases the company's leading role in advanced vehicle technology and commitment to greener transportation solutions.
The initial prototype of this innovative architecture was delivered in approximately six weeks, with the design reaching production readiness within just two months. This rapid development cycle demonstrates XD THERMAL's commitment to innovation in electric vehicle technology.
One of the key benefits of this new architecture is the 25% reduction in cooling-related components, achieved by integrating cooling functions directly into the battery casing. This integration simplifies several assembly steps and enhances heat distribution throughout the battery system, which is essential for prolonging the lifespan of lithium batteries.
However, the development journey encountered several challenges, particularly in the area of system-level sealing validation. This process involved thoroughly assessing multiple interfaces, seals, and sealing pathways simultaneously, rather than treating them as separate components. To address this challenge, the engineering team designed precision instruments and conducted systematic air and helium leak tests to ensure sealing integrity and to detect minor leaks before product launch.
Another notable challenge was the establishment of a reliable production process for the multifunctional coating system. The varying surfaces of the battery casings required different insulating and thermal barrier materials, rather than a uniform coating application. Accordingly, customized fastening and masking methods were developed to ensure defined coating boundaries and a consistent application across complex geometries.
Xu, the Chief Technical Officer of XD THERMAL, stated, "Once cooling is integrated into the casing, the design boundaries change. The challenge is no longer about optimizing a single cooling plate, but about ensuring that the entire structure delivers stable thermal performance while remaining feasible for manufacturability."
To facilitate this comprehensive approach, teams across thermal management, structural integrity, process engineering, quality assurance, and manufacturing have collaborated closely throughout the development phase. This synergistic effort allowed the insights gathered from prototypes to inform and enhance design and process revisions directly.
The scalable architecture developed by XD THERMAL can be adapted to various vehicle platforms, battery sizes, and capacity requirements without the need for a fundamental redesign of the cooling concept. Since early 2025, the company has expanded its thermal management operations for commercial vehicles, dedicating manufacturing resources for larger-format battery cooling components and achieving volume production by year-end. This manufacturing base now supports electric bus programs and heavy vehicles beyond the initial platform, integrating engineering, validation, and production resources into a unified workflow suitable for programs with diverse battery dimensions and structural needs.
Furthermore, XD THERMAL will actively participate in the IAA TRANSPORTATION 2026 event in Hannover this September, hosting discussions on battery integration, manufacturing capability, and the transition from prototype to series production in collaboration with industry partners. This involvement showcases the company's leading role in advanced vehicle technology and commitment to greener transportation solutions.
Topics Consumer Technology）
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