The Significance of Stress Analysis in the Structural Integrity of Batteries

Finite Element Analysis (FEA) stress analysis plays a crucial role in ensuring the structural integrity of our components, employing a set of theoretical verifications that combine both hand calculations and computer simulation models.

BOLDhp frequency response analysis

What is Stress Analysis?

Stress analysis is a set of theoretical verifications to assess the structural integrity of a component. These verifications are composed by both hand calculation and computer simulation model.

Types of Stress Analysis

Stress analysis is broadly categorised into three main simulation types:

  • Linear Static Analysis:

Considered the simpler structural simulation using Finite Element Method (FEM). Preferred for its simplicity but may not accurately represent variations in component stiffness or strength during operation.

  • Nonlinear Static Analysis:

Accounts for variations in material properties, contact and boundary conditions due to deformation. Essential for scenarios like high-pressure loads causing changes in structural stiffness, buckling analysis, and plastic deformations, among others.

  • Dynamic Analysis:

Yields results as a function of time or frequency. Utilised to assess the effects of vibration, shocks, and inspect resonance phenomena in structures.

Crucial material properties influencing stress analysis include:

  • Young modulus, related with the material´s stiffness.
  • Yield limit defines the stress point where deformations become permanent.
  • Ultimate Strength indicates the stress value leading to material failure.
  • Stress strain curve for nonlinear materials
Stress strain curve for Aluminium AW 5754-H12

Applications of Stress Analysis

At BOLD, stress analysis is performed on various mechanical components within batteries, using leading simulation software which offers fully-integrated CAE solutions.

Accurate stress analysis is vital in the work carried out at BOLD as it provides insights into whether a design is oversized and gives insights crucial for correlating with lab test data, ensuring a balance between design robustness and efficiency. Stress analysis aids in identifying design weaknesses before manufacturing, preventing failures during the product’s life cycle. By avoiding component breakage, it contributes to product safety and user damage prevention.

Benefits of Stress Analysis

Stress analysis allows our designers to optimise battery performance and reduce costs. Analysing regions with low stresses enables adjustments to dimensions, thickness, and other parameters, leading to a more efficient design.

One significant advantage is the reduction in the number of required tests, streamlining the product development process and saving resources.

Adding Value to BOLD’s Products/Design Services

Stress analysis provides a comprehensive understanding of component structural behaviour, facilitating a faster transition to a mature and functional design. This, in turn, adds substantial value to BOLD’s products and design services by ensuring reliability, efficiency, and safety.


BOLDair FEM Model. Internal core and inserts

2023 saw the launch of BOLDair, BOLD’s off-the-shelf aviation battery system designed to power electric or hybrid flight. In the development of BOLDair, our engineers carried out a number of simulation tests to ensure the battery was structurally sound, during stresses from Crush, Vibration, Overpressure and Underpressure testing. The process simulated and analysed the behaviour of structures or components under various demanding conditions, eliminating the risk of failure, cracks, leakage, or exterior component interference.

BOLDair FEM plies detail of the carbon fibre laminate

The results determined containment of fragments, flames, and emissions within the battery as well as ensuring there is no interference from external components. Crush tests also illuminated any risk of potential rupture, deformation, or displacement while examining dimensional tolerance limits to ensure there are no internal clashes. The test also indicated that the battery would withstand physical damage and allowed the recording of any irregularities in voltage or current.

BOLDair Modal analysis results
BOLDair UNE 38.3 Sinus Sweep Vibration displacements response.

We can match interfaces with suppliers, ensuring compatibility, seamless integration, and optimised performance. Collaboration with suppliers enables a thorough examination of potential stress points, leading to the development of cost-effective and reliable solutions that meet regulatory standards. This approach not only enhances safety and reliability but also helps identify and address issues early in the design phase, saving costs associated with modifications.

At BOLD, we pride ourselves on employing a meticulous approach to validate and elevate designs, with stress analysis serving as a pivotal element in our mechanical and structural engineering domain. This commitment ensures the durability and optimal performance of our products and designs. Clients can rest assured that our systematic approach not only prevents failures but also maximises efficiency and performance. If you’re interested in delving deeper into our design process or exploring any of our products, feel free to reach out to a dedicated member of our team at

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