XD THERMAL Dual-Sided Liquid-Cooling Architecture for Electric Bus

XD THERMAL Develops Dual-Sided Liquid-Cooling Architecture for Electric Bus Battery

On September 1, XD THERMAL announced that it had completed development of an XD THERMAL dual-sided liquid-cooling architecture for a European electric bus platform. The platform uses a 35.3-kWh battery system that combines liquid-cooled enclosures with stamped top plates, allowing heat to be managed from both sides of the battery modules. According to the company, the prototype was delivered in approximately six weeks, while the design reached production readiness within two months. The development focuses on integrating thermal management into the battery enclosure while supporting a transition from prototype development toward series production.

Integrated Battery Cooling Reduces Component Requirements

By integrating cooling functions directly into the battery enclosure, XD THERMAL reduced the number of cooling-related components by 25%. The approach is designed to combine battery enclosure and thermal-management functions rather than treating cooling as a separate set of components. During development, the team created precision fixtures and carried out staged air-leak and helium-leak testing to verify overall sealing integrity. The testing process was also used to detect low-rate leakage before the design was released. These manufacturing and validation steps supported the rapid development cycle and helped prepare the architecture for production requirements.

Manufacturing Processes Support Production Readiness

The battery development also included specialized manufacturing methods intended to maintain consistent coating boundaries. XD THERMAL developed tailored hanging and masking methods to keep coating boundaries clear during production. These processes complement the precision fixtures and staged leak-testing procedures used to validate the battery enclosure. Together, the measures address both the functional sealing requirements of the cooling architecture and the manufacturing considerations involved in producing the integrated enclosure. The development demonstrates an emphasis on manufacturability alongside thermal management, particularly as the battery system progresses from prototype construction toward series-production readiness.

IAA Transportation 2026 to Highlight Battery Integration

The company will also participate in IAA Transportation 2026, where it plans to discuss battery integration, manufacturability, and the transition from prototype development to series production with industry partners. The event will provide a platform for Europe-focused electric mobility stakeholders to examine the development approach and its production implications. XD THERMAL's completed architecture combines thermal-management integration, enclosure design, sealing validation, and manufacturing processes within the same development program. Its reported 25% reduction in cooling-related components and rapid progression from prototype delivery to production readiness are key aspects of the company's latest electric bus battery development.

Frequently Asked Questions

What did XD THERMAL develop for the European electric bus platform?
XD THERMAL developed an integrated dual-sided liquid-cooling architecture for a European electric bus platform using a 35.3-kWh battery system. The architecture combines liquid-cooled enclosures with stamped top plates, enabling heat management from both sides of the battery modules. The company reported that the prototype was delivered in approximately six weeks and that the design reached production readiness within two months. By integrating cooling functions into the battery enclosure, the design also reduced cooling-related components by 25% while incorporating air-leak and helium-leak testing for sealing validation.