Novelis, Shape Corp., and Metalsa are partnering to collaborate on testing, studying, and advancing electric vehicle (EV) battery tray concepts using aluminum roll forming technologies. The collaboration combines expertise in advanced roll forming, next-generation alloy development, and precision assembly to meet growing demand for the automotive EV sector.
“The strength and expertise of this partnership is unmatched,” said Jamie Zinser, vice president, Automotive, Novelis North America. “By combining our respective leadership in advanced roll forming, precision assembly and next-generation alloy development, we’re well positioned to advance industry standards in the EV battery enclosure market. This collaboration underscores shared commitments to sustainability and innovation, as we work together to develop high-performing, lightweight solutions that meet the growing demands of green mobility.”
Novelis specializes in the production of high-recycled flat-rolled aluminum products. The company operates an integrated network of rolling and recycling facilities across North America, South America, Europe and Asia. Recently, Novelis announced that it its 3 x 30 goals to further decarbonize its operations and products.
Shape Corp. is a global manufacturer of advanced, lightweight metal components, primarily for automobiles. The company is a pioneer of roll forming technology, which maximizes material efficiency while reducing mass, enhancing both sustainability and performance. The company has worked with Novelis previously to develop a portfolio of roll formed aluminum components for automakers.
Metalsa is a leader in product and process design, development, and manufacturing of structural components for automotive and commercial vehicles. The company specializes in in chassis structures for light and commercial vehicles.
Under the partnership, Novelis will advance alloy technology, providing high-recycled content aluminum for the design of battery structures to reduce weight and increase product strength. Meanwhile, Shape Corp. will push the limits of roll-formed aluminum applications, and Metalsa will refine complex assembly techniques to support evolving automotive demands. This is expected to lead to key technological improvements, including:
- Multi-cellular structures to optimize energy absorption and crash performance.
- Flexible part design that enables tooling reuse across multiple vehicle platforms.
- Precision assembly techniques ensuring quality and minimizing variances.
- Advanced roll forming strategies that push the boundaries of bendability and structural integrity.
“This partnership represents a major milestone in roll-formed aluminum adoption for EV structures,” said Ed Pleet, chief technology officer at Shape Corp. “By utilizing advanced roll forming and Novelis’ high-strength aluminum, we are not only redefining how battery enclosures are designed for both performance and sustainability, but also unlocking new opportunities to apply this technology across a range of structural automotive applications, further advancing lightweighting and efficiency.”
In addition, Metalsa will bring its rigorous validation processes — including front- and side-impact resistance testing, leak detection, and structural integrity assessments. This will ensure the highest standards of safety and durability. “With an eye on the future, adaptability, and diversification, the partnership has also advanced rapid prototype technologies, shortening product realization cycles and enabling faster time-to-market for components,” noted Eduardo Martinez Leal, project leader, Metalsa.
Beyond its immediate impact on EV battery enclosures, this partnership underscores a commitment to collaboration and innovation, setting a strong foundation for future advancements.