Zheng Li

Through 2023 to 2024, I worked on developing a general battery pack platform for next generation vehicles using unbox manufacturing architecture. As a side impact load case owner, I successfully delivered a battery pack structure from concept status to pre-production level (including pack enclosure, cell modules, cell potting, side sill, etc) with high crash safety margin and minimal cost per FMVSS 214 side pole regulations and Tesla internal high-standard safety guide. This battery pack will be served as a core assembly in high voltage system for Cybercab.

In order to achieve world quickest circle time for large volume production in all giga factories, I investigated the feasibility to replace traditional spot weld solution with a novel remote spot laser weld solution, which is used to weld stamping parts from body-in-white (BIW) to sustain high structural load from side impact. Through finite element analysis and actual mechanical test validation in various levels (coupon-level, component level, full vehicle level), I successfully delivered an optimal remote laser weld solution which reduced single weld time significantly. This novel laser weld solution will be used in production of Cybercab.

Cybercab was first revealed to the public on Oct 10th, 2024.