PLASMA-POWERED JOINING & ASSEMBLY SOLUTIONS FOR NEXT-GEN EVs
Terms of Use | Privacy Policy | Transparency in the Supply Chain © 2024, STANLEY Engineered Fastening. All Rights Reserved.
Our leading brands
STANLEY Engineered Fastening has been a driving force in automotive innovation for nearly a century, empowering the industry with cutting-edge fastening and joining solutions. As a key partner to the world’s leading auto manufacturers and suppliers for modern EVs and hybrids as well as traditional ICE-powered automobiles, we are at the forefront of the future of automotive technology. Our pioneering Plasma Joining Technology, No-Hole Fastening, Eco-Fastening Platform, Self-Pierce Riveting, and automated assembly technologies redefine vehicle assembly with superior multi-material joining and welding solutions to enhance manufacturing efficiency and performance of safer, lighter EVs and hybrids. We also provide innovative thermal and pressure management solutions for EVs and advanced components for battery pack applications. Discover our tailored, sustainable, and cost-effective solutions designed to overcome the toughest multi-material assembly challenges, turning your EV manufacturing goals into reality.
Redefining the Future of EV Engineering
Our wide portfolio of automated assembly systems, innovative welding processes, and integrated tools for EV and hybrid manufacturing – including Plasma Joining Systems for multi-material applications, Assembly Solutions for Castings, Self-Piercing Rivet Systems, and more – enables the EV industry to maximize production and efficiency at scale across the assembly line. Our team of EV experts and engineers can help you reduce your manufacturing complexities and experience more streamlined, custom single-supplier solutions.
Joining & Welding Solutions for Castings
Learn More
Home
Thermal Management
Battery Pack Applications
Joining Solutions for Casting
About Us
Events
LEARn more
22 - 24 January, 2025
Tokyo Big Sight, Japan
meet Us at Booth #E38-8
Our technologically advanced, automated No-Hole Fastening and Welding Systems offer significant advantages by eliminating the need for holes in the car body of EVs and hybrids. It also significantly reduces the chances of corrosion, vibration, and loosening in the vehicle body. This technology creates strong, secure joints between components without compromising structural integrity. When implemented with the new POPNut MechSeal blind rivet nut, it delivers superior mechanical sealing across multiple applications.
No-Hole Fastening
This innovative eco-friendly system leverages No-Hole Fastening technology to offer a suite of standardized solutions designed to cover over 90% of your fastening needs and applications with just a handful of components. EFP not only provides versatile components, it enables efficient vehicle production with lightweight materials, reduced CO2 emissions, and recycled plastics.
Eco Fastening Platform (EFP)
Our thermal and pressure management solutions for EVs and hybrids are an exceptional step forward in addressing the persistent challenge of overheating and swelling in lithium-ion batteries. Our systems enable superior thermal insulation as well as heat distribution and dissipation capabilities, along with pressure regulation, to not only enhance overall battery performance but also mitigate the risks related to thermal runaway and EV battery fires.
We collaborate with equipment manufacturers, automotive tiers, and battery and charging manufacturers to develop state-of-the-art joining and welding solutions for battery packs to complement EV manufacturing – making EVs and hybrids lighter, safer, and more efficient.
Our EV experts at STANLEY Engineered Fastening have analyzed the problem of thermal runaway in detail to understand its mechanism in lithium-ion batteries, which enables us to develop integrated, cutting-edge solutions to prevent its occurrence.
Mechanism of
Thermal Runaway
It’s clear that EVs are the future, with multiple benefits for users, automakers, and – most importantly – the environment
However, there are complexities in EV battery technology that all manufacturers must explore in detail to ensure safety and help prevent battery fires
DOWNLOAD OUR EXPLAINER FOR IN-DEPTH INSIGHTS
in EVs are susceptible to thermal runaway
Lithium-ion batteries
fires and explosions
Could lead to major
Leading to extensive damage
to your vehicle,
property, and – at worst – loss of life
Runaway
Self-heating of battery begins at T(runaway), which varies from about 130°C to over 200°C Leads to fire, explosion & destruction of the battery
Ramp
Battery temperature rises above T-onset to 80°C, which leads to Solid-Electrolyte Interface (SEI) decomposition Electrolyte decomposes and/or separator begins to melt at 100–120°C Cathode breaks down above 130°C & cell becomes highly flammable
Onset
T-onset >55°C when battery is subjected to electrical or thermal abuse
operating temperature
Normal operation for EV batteries is 15-45°C 21.5°C is the optimal temperature
Mechanism of Thermal Runaway
Preventing Thermal Runaway
If used to substitute an existing thermal management solution, this will result in an overall reduction in the weight of the battery pack and increase the range of the vehicle. The Thermal Fin can also be used as part of a more significant lightweighting design strategy, reducing the number of cells required in a pack to achieve a specified power output, resulting in huge reduction in weight and cost of the battery pack.
The Thermal Fin has an advanced lightweight design
from STANLEY Engineered Fastening simultaneously acts as a thermal barrier, preventing heat transfer between cells, and a thermal conductor, transferring heat in both directions to maintain ideal operating temperature.
The Thermal Fin
EV battery engineers are constantly challenged to increase the capacity of the battery to deliver
More power and more range for the vehicle.
Typically, there are two methods to achieve this:
If the number of cells increases, so does the design space and overall weight of the vehicle, which in turn has a negative impact on its range.
Increase the number of cells
increasing the energy density of each cell can make them more susceptible to overheating and could result in more battery fires
Increasing the energy density of each cell can make them more susceptible to overheating and could result in more battery fires.
Increase the energy density of the cell
EV battery engineers at STANLEY Engineered Fastening have delivered innovation against a third option – eliminating battery drain and energy loss by developing mechanical solutions to maintain optimal temperatures within the battery system to improve overall performance.
The ideal operating temperature for an EV battery ranges from
25°C to 35°C.
How efficiently it will transfer heat.
Any deviation can impact how much energy the cell can store and
Fluctuations of 40°C.
Fast charging and vehicle acceleration during standard operation can cause temperature
Performance by as much as 30%.
This extreme deviation from optimum operating temperature can impact
Preventing
How to improve EV performance and safety
As solution providers to the world’s leading auto manufacturers and industry suppliers, STANLEY Engineered Fastening has nearly a century’s worth of innovative solutions, expertise, and collaboration experience to empower the auto industry toward an electric future. Our role is not just to provide innovative products but to enable quick access to the tools, information, and engineering prowess that our customers require to achieve success in the EV domain.
EXPLORE OUR WIDE RANGE OF EV & ENERGY STORAGE SOLUTIONS
No Hole Fastening
Book a meeting
Plasma-Powered Joining & Assembly Solutions for Next-Gen EVs
Join STANLEY® Engineered Fastening at
Get exclusive access to
January 22 - 24, 2025
Plasma Joining for Aluminum Casting and High-Tensile Strength Steel
How plasma joining for multi-material applications can transform EV production
Tucker Plasma Joining
Self-Pierce Riveting
Stud Welding Systems
no-hole fastening
Blind Riveting
Mori Daisuke
23 January, Thursday
11.00-11.30 AM
Director, R&D
Stanley Black & Decker
24 January, FRIday
POPNut MechSeal: Best-in-Class Blind Rivet Nut for IPX7 and Automation
Eliminate O-Rings, simplify assembly, and meet IPX7 standards to deliver high-performance automation
SUPERIOR LIGHTWEIGHT JOINING FOR EVs
MEET us at BOOTH #E38-8
GROUNDBREAKING PLASMA TECHNOLOGY
LIVE PRODUCT DEMOS
ECO-FRIENDLY, SUSTAINABLE FASTENING SOLUTIONS
EXPERT CONSULTATION
Explore Our Next-Gen Joining & Fastening Systems
leadership Seminars
POWERED BY PLASMA
STANLEY Engineered Fastening is a comprehensive solutions provider in the automotive industry that can help you take your electrification project to the next level at unprecedented scale and efficiency – with battery pack components, thermal management solutions, and game-changing innovations that make EVs safer, lighter, and more efficient. We leverage a unique combination of assets and insights to help industry leaders and engineers drive innovation in electric mobility and battery pack applications. A comprehensive solutions provider, STANLEY Engineered Fastening can help you take your electrification project from design to production – seamlessly.
HYPERCHARGING INNOVATION FOR A SAFER ELECTRIC FUTURE
Drive into the future with safer EV battery solutions that leverage our unique approach to thermal and pressure management.
For manufacturing safer, lighter & more efficient EVs at scale
Battery Pack Components & Solutions
VENT PLUG
THERMAL FIN
CELL SEPARATOR
CELL TERMINAL
BUSBOLT
FASTENING SOLUTIONS
Download the brochure
Meet our EV battery experts for in-depth insights & product demos!
Automotive manufacturers have to get their fastening systems right to enable efficient production at scale and minimize costs. The fastening function has to be approved for the entire lifecycle of the vehicle and needs to be economic, reliable, easy, and safe. STANLEY Engineered Fastening’s technologically advanced no-hole fastening systems offer significant advantages by removing the need for additional sealing caused by the use of holes throughout the car body, which can create significant disadvantages, such as corrosion, vibration, and loosening.
Joining & Welding Solutions for Casting
STANLEY Engineered Fastening has been revolutionizing fastening and assembly technologies in the automotive industry for decades to make automobiles safer, lighter, faster, and more reliable. Our expertise in customized multi-material fastening, joining, and welding solutions for automotive castings – including mega- and die-casting – is a testament to our commitment to the evolving automotive domain. The challenges in automotive casting and joining are multifaceted and require a nuanced, collaborative approach. By understanding the specific needs, constraints, and material requirements of our automotive customers, STANLEY Engineered Fastening offers tailored, sustainable, and cost-effective solutions designed to help overcome these obstacles. Explore our wide portfolio of fastening, joining and assembly systems and tools built to handle even the toughest multi-material casting challenges – then let’s get started turning your challenge into a solution.
No two castings are created equal. Your fastening and joining solutions shouldn't be either. Solutions designed for Small, Medium, and Large-size casting applications.
SMALL
Application: Shock Tower
Medium
Application: Battery Box
LARGE/MEGA/GIGA
Application: Front & Rear End
Contact us
Achieve High-Performance Castings: Request a Joining & Welding Consultation
Precision and innovation are critical in automotive casting. As manufacturers grapple with the challenges of lightweight materials, complex designs, and stringent environmental regulations, STANLEY Engineered Fastening's advanced fastening and joining solutions for automotive castings are turning obstacles into opportunities. From revolutionizing the joining of multi-materials to developing custom rivets that streamline production processes, we are casting a new mold for the industry. Our expertise solves casting challenges in the automotive industry – now and in the future – to ensure that as vehicles evolve, the very foundations of how they're built evolve too. Discover how STANLEY Engineered Fastening is forging the future of automotive casting.
Are You Facing Lightweight Material and Design Challenges?
Read The Whitepaper
Threaded Fastening Solutions Engineered threaded fastening solutions for critical and custom applications.
Premium Blind Rivets & Rivet Nuts Comprehensive range of high-quality engineered blind rivets, rivet nuts, and installation tools.
No-Hole Fastening & Mechanical Joining Groundbreaking automated no-hole fastening and mechanical joining systems including self-piercing, stud welding, and stud gluing.
Engineered Plastic Fasteners & Components Precision-engineered plastic fasteners and components designed to support sustainable development of EVs.
Structural Rivets & Fasteners Engineered fasteners, structural rivets, and speed rivets for specialized applications.
Reliable Blind and Torque tools Tools that delivers productivity, quality and safety to a wide range of assembly and manufacturing operations.
Stud Welding Solutions Stud welding fasteners, accessories, and equipment with limitless applications across multiple industries.
With a wide-ranging portfolio of brands and products, we can help reduce EV manufacturing complexities and provide more streamlined, custom single-supplier solutions.
STANLEY Engineered Fastening – a division of Stanley Black & Decker – is a unique and trusted design partner for the world’s largest and most innovative creators. As the global leader in precision fastening and assembly solutions, our role is not just to provide innovative products but to enable quick access to the tools, information, and engineering expertise that our customers require to achieve success. Our longstanding expertise across multiple industry segments brings nearly a century’s worth of valuable knowledge, products, and collaboration experience to empower our customers to accelerate toward an electric future.
Share Your Experience
English
Japanese
Upcoming Event
22 - 24 January 2025
This year’s NA Battery Show featured a packed Open Tech Forum Theater with engaging discussions on battery pack design, recycling, gigacasting, and thermal management. Key sessions included Dezarai Shepherd's insights on EV battery safety and performance, and Tim McElgunn's overview of automated solutions for EV and hybrid vehicle production.
PAST Events
OCT. 07 - 10, 2024
Huntington Place Detroit, MI
22 - 24 October 2024
Allerpark | Wolfsburg | Germany
NA Battery Show 2024: Event Highlights and Key Takeaways
Check out the replays to catch up on these groundbreaking innovations.
Thermal Innovations for EV Battery Safety: Unveiling Next-Gen Solutions
Automated Solutions for Speed, Simplicity & Serviceability of Battery Pack Assembly
Missed the live sessions?
Breakthrough innovation when it comes to joining of dissimilar high-strength and ultra-high-strength materials.
Challenges in the Automotive Industry
Mixed material usage is rapidly increasing, with innovative solutions required to join dissimilar materials with varying thicknesses and hardness.
Tucker Plasma Joining - A Multifaceted Solution
STANLEY Engineered Fastening’s innovative new process uses our existing plasma torch to soften the top layer, allowing the pin to be pushed into the material.
Single-sided access No need for pre-drilled holes Joining UHSS to aluminum castings Heat treatment supports joining of brittle castings Hybrid joining of multi-material layers For materials up to 2,000 Mpa
Back to MAIN
Casting Application
Tucker Plasma Joining helps address the unique casting material challenges and is best suited to:
Connect adjacent parts Fully close battery box lid
Self-Pierce Riveting (SPR)
An Industry-Leading Joining System for Mixed-Material Automotive Castings
Tucker SPR equipment allows you to join materials and castings that cannot be welded easily – including aluminum-aluminum, aluminum-steel, and high-tensile steel – by combining two technologies in one modular system: self-piercing rivets with semi-hollow rivet and punch rivet.
Join two or more layers of materials and castings without the need for a pre-drilled hole Achieved by inserting a rivet and cold-forming an interlock Cycle times similar to spot welding 100% servo-electric drive ensures highest level of process control and repeatability Large selection of C-frame sizes and configurations to meet application requirements Tools can be robot-carried or pedestal-mounted System can control up to three tools with a single control unit Customized joining solutions for a wide range of geometries
The SPR Advantage
Innovative Solution for Joining Processes:
Add structural stability inside battery box
Stud Welding Systems (SWS)
Technologically Advanced Stud Welding to Enable Reliability and Energy Efficiency on a Unified Platform
Usage of multi-material alloys Varying thickness and hardness Positional accuracy Surface contamination Reliability Lightweighting
Casting Applications
Aluminum fixing Wire harness Grounding
The Tucker Stud Welding Advantage
High operational reliability and precision Mixed-material compatibility Tucker CleanJet removes surface contamination Compact design Sustainable and energy-efficient solutions Remote monitoring Connected systems on a unified platform
Coolant lines Module fixation
Our Engineered Rivets and Cordless Fastening Tools are Compatible with a Wide Range of Mixed Materials, Ensuring Maximum Reliability, Lightweighting, and Faster Installation
Complicated installation processes Compatibility with different casting materials Ergonomic challenges on assembly floors Recyclability and sustainability Lightweighting
Aluminum fixing Wire harness Grounding Coolant lines Module fixation
Key Benefits of Our Blind Riveting Solutions
High operational reliability, precision, and joint strength Optimized TCO Single-sided access Joining and fastening of mixed materials Cordless installation tools (NB08PT-18 and PB2500 Smart) Quick and simple installation process Industry-leading joint integrity Sustainable solutions No heat effect
Serviceable battery pack enclosure Battery tray assembly applications Attachment points for connector housings Sealing plugs for holes in die-casted materials Cell fixation plates Busbar joints Car seat attachment applications
no-Hole Fastening
While the use of casted parts helps reduce the overall number of fastening requirements, the components still need to be assembled, mounted and joined together – and benefits of using a no-hole fastening method still remain. In fact, with the heightened concern of many large-scale casted parts being unrepairable, preventing damage from occurring grows increasingly more important.
