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Custom Aluminum Extrusion for Energy Storage

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  • Aluminum Extrusion for Energy Storage

Aluminum Extrusion for Energy Storage

The rapid expansion of lithium-ion battery systems for electric vehicles, grid-scale energy storage, and portable power applications is driving significant demand for precision aluminum extrusion profiles in battery module and pack construction. Aluminum's combination of light weight, thermal conductivity, electrical isolation capability (when anodized), and recyclability makes it the material of choice for structural and thermal management components within battery systems.

Our energy storage extrusion solutions are primarily built on 6063 and 6101 alloys. 6063 provides the structural integrity, corrosion resistance, and surface quality required for battery module trays, upper and lower support brackets, and inter-module connection structures. 6101, with its optimized electrical conductivity (approximately 55% IACS), is specified for busbar and flexible connector applications where current-carrying efficiency is a design constraint.

Profile geometries are engineered to integrate thermal management channels directly into the structural section—allowing coolant to circulate through the extrusion itself and eliminating the need for separate heat exchanger components. This approach reduces part count, lowers assembly weight, and improves thermal uniformity across the cell stack. Wall thicknesses and channel dimensions are optimized through thermal simulation to meet module-level temperature management targets.

We work with battery system integrators and EV manufacturers from the concept stage, supporting die design, alloy selection, thermal analysis, and first-article qualification. Dimensional consistency across production batches is maintained to the tolerance requirements of automated module assembly lines.

  • Details

Applicable Material

Core Function

Technical Implementation

Application Value & Industry Compliance

Primary material is 6063-T6 grade aluminum alloy, paired with 6101-grade aluminum alloy conductive/thermally conductive components; combines high strength, high thermal conductivity, light weight, and excellent machinability

Core load-bearing structural component of the battery module, providing cell positioning, fixing, protection, and heat dissipation — the core skeleton of the battery module, bearing cell weight, vibration/impact loads, and thermal loads

1. 6063 aluminum alloy achieves a balance of high strength and high toughness through solution treatment plus artificial aging, suited to integrated forming of ultra-thin walls;
2. Surface treated with anodizing plus ceramic coating to improve corrosion resistance and insulation performance;
3. Structural design integrates cooling channels for rapid heat dissipation from the cells;
4. Precision CNC machining ensures assembly accuracy of holes and latches

1. Complies with GB/T 31484/31485/31486 new energy vehicle battery industry standards;
2. Ensures battery module structural integrity under vehicle vibration and temperature cycling, preventing cell displacement or deformation;
3. Achieves a lightweight battery module design, improving vehicle range;
4. Efficient heat dissipation ensures consistent cell operating temperature, extending battery cycle life

Primary material is 6101-H18 grade aluminum alloy, paired with 6063-grade aluminum alloy fixing components; combines high conductivity, high toughness, fatigue resistance, and excellent weldability

Core conductive connection component between cells within the battery module, carrying current for series/parallel cell connections, while accommodating expansion and contraction during cell charge/discharge cycles and cushioning vibration and impact

1. 6101 aluminum alloy achieves a balance of high conductivity and high toughness through precise rolling plus annealing, suited to flexible bending and stamping;
2. Surface treated with nickel/tin plating to improve weldability and oxidation resistance;
3. Structural design uses a flexible laminated structure to cushion displacement and stress during cell charge/discharge cycles;
4. Precision die stamping ensures dimensional consistency, suited to automated assembly

1. Complies with new energy vehicle battery module conductive connection safety standards, avoiding overheating or arcing risk at connection points;
2. Accommodates expansion/contraction during cell charge/discharge and cushions vehicle vibration, ensuring connection reliability;
3. Low-resistance design reduces current transmission loss and heat generation, improving battery module energy efficiency;
4. No cracking or oxidation over long-term use, ensuring stable electrical performance throughout the battery module’s lifecycle

6063/6101 grade aluminum alloys are both recyclable, environmentally friendly materials, releasing no hazardous substances, and comply with domestic and international automotive industry environmental standards

Dedicated structural components for new energy vehicle battery modules, suited to demanding vehicle environments, balancing structural safety, electrical safety, thermal management, and environmental compliance

1. 6063/6101 aluminum alloys are both halogen-free, low-VOC environmentally friendly materials, with no heavy metal or hazardous volatile emissions during production;
2. Heat treatment and surface process optimization suit high/low temperature, high-vibration, and high-corrosion vehicle environments;
3. Structural design complies with automotive industry safety standards, achieving electrical insulation and fire/flame-retardant protection

1. Meets environmental and safety access requirements for domestic and international new energy vehicle markets, reducing product compliance risk;
2. Suited to all vehicle-mounted use environments, ensuring safe and stable operation of the battery module throughout its lifecycle;
3. Aligns with the automotive industry’s trend toward lightweighting and green manufacturing

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Suzhou Dihong Aluminum Co., Ltd.
Founded in 2014, Suzhou Dihong Aluminum Co., Ltd. has evolved from a single-product aluminum distributor into a modern technology enterprise integrating aluminum distribution, aluminum extrusion, CNC machining, and precision stamping. The company has established production bases in Huishan, Wuxi, and Wujiang, Suzhou, primarily serving industries such as 3C, photovoltaics, new energy vehicles, medical equipment, and aerospace. Aluminum Extrusion for Energy Storage Suppliers in China.
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Suzhou Dihong Aluminum Co., Ltd.

System Certification

We have obtained multiple international system certifications and industry qualifications. All products comply with international standards, ensuring reliable quality and long-term stable cooperation. Custom Aluminum Extrusion for Energy Storage

Suzhou Dihong Aluminum Co., Ltd. Suzhou Dihong Aluminum Co., Ltd.
  • ISO9001 ISO9001
  • IATF-16949 IATF-16949
  • AS9100 AS9100