As electric vehicles and energy storage technologies continue to evolve, the U.S. market is raising the bar for battery structure safety and reliability. Steel battery enclosures remain widely adopted by leading companies for their outstanding mechanical strength and durability, and continue to evolve alongside emerging material trends.
At the same time, XD Thermal has long focused on aluminum liquid-cooled battery enclosures, leveraging extensive industry experience to deliver efficient thermal management solutions for lithium-ion battery systems across automotive OEMs and other sectors. This article highlights 10 influential U.S. companies shaping the future of steel battery enclosures—offering practical insights and valuable references for your business.
Magna’s steel battery enclosures leverage the structural advantages of high-strength steel while offering a lower material cost compared to aluminum or fiber-reinforced plastics. Additionally, advanced design and manufacturing processes optimize battery space utilization, making Magna’s steel enclosures a durable and cost-effective choice for electric vehicle applications. Notably, Magna was recently recognized as one of the world’s most ethical companies!
While most U.S. manufacturers focus on steel battery enclosures, global suppliers like XD THERMAL in China are driving innovation in aluminium solutions. Specialising in liquid-cooled aluminium battery enclosures, XD THERMAL supports projects that prioritise lightweight design and efficient thermal performance. Its components are often integrated into systems assembled in the U.S., offering a valuable alternative for manufacturers balancing strength, weight, and heat management in EV and ESS applications.
ArcelorMittal is not a U.S. company, however, the company has a U.S. presence and offers steel solutions in the North American market. As far as I can tell, their S-in motion® steel battery pack is cleverly designed with a reinforced threshold structure that not only protects the pack, but also makes the entire box more compact while boosting energy density. It’s made of high-strength steel that ensures performance and reduces weight, allowing the EV to go further and perform better. In addition, ArcelorMittal has partnered with Valin Iron & Steel to establish VAMA, which specializes in steel solutions for the automotive industry, including steel battery cases for electric vehicles, so you can find out more about it if you are interested.
They manufacture a battery enclosure with a newly developed steel design for superior performance. It consists of a housing with a frame, connecting profiles, upper and lower support arms, anti-drill impact guards and cover plates. And with a variety of patented designs to choose from, it is virtually weight-neutral compared to aluminum. In addition, the company proves that light weight, safety and fire resistance can be combined with significant cost savings. I also learned that ThyssenKrupp is participating in Coiltech Germany, a trade fair for the solenoid and winding industry, from March 26 to 27, 2025.
Voestalpine has been focusing on materials research for core electric vehicle components since the early stages of development, providing the right steel for battery enclosures, such as duplex steels for covers, compound steels for crash protection, mild steels for cooling panels and highly ductile compound steels for structural components. In addition, they are working with Bertrandt to develop solutions for economical electric vehicles by introducing an ECE-R100-compliant scalable steel battery enclosure designed for mass production that combines economy, sustainability and safety to make electric vehicles lighter, safer and more reliable.
Gestamp is an international group dedicated to the design, development and manufacture of automotive metal parts. They have a wide range of products that are widely used in body structures and play a key role in the overall design of the vehicle. In addition, the company covers the complete value chain from the manufacturing of molds and stamping equipment to the production and finishing of products, which can ensure the efficiency and integration of the production process. Of course, the company has extensive experience with steel battery enclosures, providing solutions that meet all requirements for lightweighting and safety.
BENTELER has many years of experience in the production of battery enclosures. For the development of the concept for the steel battery box, they also took special account of the requirements and solutions for the entire project in terms of corrosion protection, sealing and connection technology. In addition, the project will undergo a complete life cycle analysis to fully assess the environmental impact compared to the reference model. I also recently learned that their plant in Fuzhou, China, has won a trio of awards: Fujian Benz honored them with the titles of “Quality Excellence” and “Outstanding Supplier,” as well as the BOS Compass Bronze Award.
TRB está especializada en la fabricación de carcasas ligeras de composite para baterías de vehículos eléctricos. Estas carcasas están fabricadas con materiales compuestos avanzados que proporcionan el equilibrio perfecto entre resistencia, seguridad y diseño ligero. Al utilizar materiales compuestos, las carcasas no sólo reducen el peso total del vehículo, sino que también proporcionan una mejor gestión térmica para mantener las baterías frías y rindiendo al máximo. Además, la empresa se complace en anunciar la fabricación con éxito de un suelo de balsa y aluminio de repuesto como parte de la remodelación por parte del B-17 Charitable Trust del Sally B, el último avión B-17 Flying Fortress en condiciones de volar que queda en Europa.
Although the company is headquartered in Finland, it has a subsidiary in the United States. Its stainless steel plant in Calvert, Alabama, is an important part of the Americas business. the Forta H series for Outokumpu battery casings, which develops a new generation of fully austenitic stainless steels, opens up new opportunities in lightweight engineering and design thanks to a yield strength of Rp0.2 ≥ 1000 MPa, combined with high elongation at break. new opportunities. In addition, they have a strong focus on the circular economy and use 95% recycled materials in their products, ensuring that the materials are not only durable but also fully recyclable.
The company is a subsidiary of the Volvo Group, and in addition, I understand that Volvo Trucks North America uses a battery box made of stainless steel in their Volvo VNR Electric electric trucks. This design meets the need for battery support, durability, and protection of cab occupants and vehicle components. Just recently, let’s all congratulate Jon Pritchett, CEO of Nextran Truck Centers, on receiving the prestigious 2025 Horatio Algiers Award.
Linamar Corporation is a leading global supplier of precision products for light vehicles, commercial trucks, off-highway vehicles, energy and industrial manufacturing. Notably, in 2023, Linamar acquired Dura-Shiloh’s battery box business for $325 million in cash. The acquisition covers three plants in Alabama, USA, the Czech Republic and North Macedonia, which specialize in the production of advanced battery enclosures for electric vehicles, further strengthening Linamar’s presence in the new energy market.
He trabajado en la gestión térmica de baterías durante más de 5 años, ocupándome de muchos proyectos internacionales. Si tiene curiosidad sobre los productos o servicios de refrigeración líquida de baterías, ¡no dude en hacerme cualquier pregunta!
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