Project Background
With the rapid development of battery-swapping solutions in Europe, Fiat launched a modular swappable battery version of the Fiat 500 EV for urban mobility platforms. The project required a lightweight and maintainable chassis with a high-strength structural battery box. Baoxuan Precision Manufacturing was brought in as the sheet metal solution provider for structural design and fabrication.
Requirements & Challenges
- Swappable battery box must support fast installation and IP67 sealing
- Undercarriage sheet metal structure should be both lightweight and strong
- Surface finishing must withstand outdoor exposure
- All components must comply with ECE and ISO 26262 standards
Our Solutions
- Optimized Structural Design: Laser-cut and bent reinforcement structure reduced weight by 18%
- Enhanced Protection: Robot welding + industrial sealant for water ingress prevention; passed 1000h salt spray test
- Surface Finishing: Eco-friendly powder coating + corrosion-resistant primer coating
- Rapid Sample Delivery: From DFM support to prototype approval in just 72 hours
Client Testimonial
“With Baoxuan, we found an engineering and supply team that responded fast and understood the specific structural needs of battery-swapping EVs. They are a key partner in our EU EV platform.”
——Project Leader, Fiat Europe R&D Center
Results
✅ Over 5,000 battery chassis delivered with consistent quality
✅ On-time delivery rate over 98.9%
✅ Visual and surface quality passed VDA 6.1 standards
✅ Recognized as a “Technology Support Supplier” by Fiat
Are you also looking for a sheet metal structure + new energy chassis solution partner?
Need modular chassis or EV battery box fabrication? Let Baoxuan be your partner in innovation.
