Maxion InVolt: Lighter EV battery housing

Maxion Structural Components and Novelis have jointly unveiled the Maxion InVolt, a new battery housing for electric commercial vehicles. The component is stamped from a specially developed rolled aluminum alloy.

According to the companies, the InVolt housing is approximately 35% lighter than an extruded aluminum housing built to the same technical specifications. The design is adaptable for vehicles ranging from light to heavy commercial models. A global market launch is planned.

Weight and Cost Advantages

Reducing weight is a primary challenge for battery-electric buses and trucks. Maxion states that the stamped aluminum approach is more cost-effective than current processes. It also allows easier access to internal components for maintenance purposes.

Stamped aluminum is already a common material in automotive manufacturing. The new alloy and process aim to translate those benefits directly to the commercial EV sector.

Material and Sustainability Benefits

Novelis, which provided the raw-material expertise, highlights aluminum's suitability for electric commercial vehicles. The metal offers a combination of low weight and impact absorption, which meets safety and performance demands.

The company also emphasizes aluminum's sustainability credentials. It is repeatedly recyclable without losing its properties. Novelis claims this recyclability can reduce greenhouse gas emissions by up to 95%.

“With over 40 years of experience in the automotive sector, Novelis is focused on co-creating innovative and customized solutions to meet the demand for more sustainable mobility,” said Daniele Albagli, Vice President of Sales for Novelis South America.

Strategic Development Goals

The partnership is framed as a strategic move to address core challenges in commercial electric vehicle design. Reducing vehicle weight directly influences range and efficiency, key factors for fleet operators.

“The development of this solution represents a key step in our strategy to reduce the weight of electric commercial vehicles and, consequently, contribute to reducing CO₂ emissions without compromising vehicle load capacity,” said Marco Tulio Ricci, Global Director of Innovation and Engineering at Maxion Structural Components.

The InVolt housing is presented as a scalable solution intended for various vehicle classes in international markets. The development highlights the industry's focus on component-level innovations to improve overall vehicle performance and sustainability.