MAHLE has begun series production of an aluminum battery cooling plate for electric vehicles at its Montblanc plant in Tarragona, Spain. Although the new production line will primarily support the European automotive market, the underlying thermal-management requirements apply across the global electric vehicle (EV) industry.
As automakers introduce higher-power charging systems and larger battery packs, maintaining uniform cell temperatures is becoming increasingly important for vehicle performance, safety, and durability.
The cooling plate is designed to maintain battery temperatures below 40° C and distribute heat evenly across lithium-ion cells. Consistent thermal management supports fast charging, driving range, battery performance, and service life.
MAHLE invested a double-digit million-euro amount to expand and convert approximately 10,000 square metres of the Montblanc facility. Production will gradually increase from 1,000 units per week to 8,000 units per week by the end of 2026, with capacity reaching as many as 15,000 units per week depending on demand.
Manufacturing the cooling plates requires highly automated processes because of strict requirements for corrosion resistance, cleanliness, and surface quality. The production line incorporates cathodic dip coating, also known as e-coating, to provide uniform corrosion protection and adhesion. PVC surface treatments are also used in the manufacturing process.
The plates are made from recyclable aluminum. MAHLE has also installed a water-treatment system that reduces water use in the e-coating process by 95%.
The Montblanc plant employs approximately 750 people and was selected in part because of its proximity to European vehicle production and logistics networks.
Filed Under: Technology News