Austrian supplier Resch has developed a new battery module that eliminates the need for adhesives and welded connections, offering a potentially lower-cost and more sustainable alternative to conventional battery assembly methods. The company estimates up to 30% cost savings if the module enters large-scale production.
The technology, developed by the family-run firm in St. Stefan, Styria, replaces traditional bonding and welding techniques with a fully mechanical assembly system. “Instead, the cells are assembled mechanically – allowing for targeted replacement of individual defective cells without needing to discard the entire module. Think of it like Lego,” said managing director Gerald Resch, who leads the company alongside his wife, Andrea Resch.
This modular design not only simplifies disassembly and recycling but is also compatible with all standard battery cell formats. Resch began development of the concept in 2023 and says several automotive OEMs are currently evaluating it for possible series production. The company also sees potential applications in aviation, marine transport, and stationary energy storage.
Designed for automated manufacturing, the module is built on a baseplate compatible with multiple cell types and includes a variable-length carrier structure and an end plate with integrated cooling. A key innovation is the safety system that prevents thermal propagation. “When one cell overheats and ignites, it can cause a chain reaction,” Resch explained. “The new module prevents this with a folding mechanism that channels gases and particles downwards, combined with an insulating barrier that blocks heat transfer.”
“We’ve completely rethought the battery module – also with the goal of launching a market-ready solution from Europe,” Resch said, positioning the innovation as a competitive alternative to dominant Asian manufacturing methods.