Novelis, Shape Corp., and Metalsa Pioneer Roll-Formed Aluminum Advancements for Next-Generation EV Battery Enclosures

Shape Corp., Novelis, and Metalsa have partnered together to show the power and capabilities of roll-formed aluminum assemblies. This partnership integrates advanced roll forming, next-generation alloy developments, and precision assembly techniques to deliver sustainable, high-performance solutions for the automotive industry.

Shape Corp., a global leader in advanced roll forming, plays a pivotal role in the partnership, applying its expertise in forming ultra-high-strength materials into complex geometries that optimize structural efficiency. Working in collaboration with Novelis, a leading aluminum rolling and recycling company, and Metalsa, a specialist in structural vehicle components, the team has successfully developed an innovative next generation roll-form-intensive battery tray concept that enhances lightweighting, strength, and manufacturability.

Advancing the Future of EV Battery Enclosures

This initiative showcases significant advancements in roll-formed aluminum applications. By integrating Novelis’ high-recycled aluminum S650 alloy, the enclosure achieves superior weight reduction, enhanced durability, and increased sustainability in production.

“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.”

Key technological improvements introduced by Shape Corp. and Metalsa include:

• 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.

Shape Corp.’s industry-leading roll forming technology maximizes material efficiency while reducing mass, enhancing both sustainability and performance. Meanwhile, Metalsa’s rigorous validation processes—including front- and side-impact resistance testing, leak detection, and structural integrity assessments—ensure the highest standards of safety and durability.

“Metalsa is a global leader in product and process design, development, and manufacturing of structural components for the automotive and commercial vehicle mobility industries,” said Eduardo Martinez Leal, Project Leader.

“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.”

A Collaborative Approach to Innovation

“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.”

Shaping the Future of Mobility

Beyond its immediate impact on EV battery enclosures, this partnership underscores a commitment to collaboration and future innovation setting a strong foundation for future advancements. Shape Corp. continues to push the limits of roll-formed aluminum applications, while Novelis advances alloy technology, and Metalsa refines complex assembly techniques to support evolving automotive demands.