Vehicle Design & Development

Propulsion System Development & Integration

Optimal EV Propulsion System

Battery Pack, BMS & E-Drive

Optimal has extensive experience of creating electric vehicle platform systems that integrate the battery pack housing, electric motors, gearbox and the front and rear suspension systems.Balancing conflicting requirements effectively to ensure vehicle range, safety targets and dynamic performance are all satisfied.

  • Optimized battery housing that is efficiently integrated with the BIW to achieve global stiffness requirements
  • Propulsion system packaging with front and rear chassis subframes including dynamic movement clearance checks
  • Development of component & system installation including tool access

Battery Development Capabilities

Optimal has a dedicated team of battery experts that have been developing electric vehicle battery systems for over 20 years.

Batteries for electric vehicles

Optimal’s battery development capabilities include:

  • EV Battery benchmarking
  • Select battery chemistry to match vehicle performance
  • Module design and development
  • Cell to cell and cell to bus bar welding analysis
  • Pack design and development
  • Thermal management analysis
  • Safety/crash analysis
  • BMS development, electrical wiring and controls development
  • Prototype build
  • Testing & Validation

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Benchmark an existing vehicle in same class

Optimal has developed a proven 28-month vehicle launch process utilizing a benchmark vehicle to help guide the design for a unique new vehicle of any class.  This innovative process includes the following steps:

  • Select benchmark vehicle
  • Performance benchmarking
  • Full vehicle model recovery
  • Optimize new vehicle for aerodynamics, crash, NVH, durability
  • Determine new vehicle technical specifications
  • Create unique powertrain, exterior/interior design to fit optimized body envelope
  • Develop prototypes for testing and homologation
  • Launch new vehicle production

28 month vehicle launch process28-month vehicle launch process
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Design based on Optimal’s best in class vehicle model database

Optimal has developed a proven 18-month vehicle launch process utilizing a database of best in class benchmark vehicles to help guide the design for a unique new vehicle of almost any class.

This innovative process includes the following steps:

  • Determine new vehicle class and technical specifications
  • Optimize new vehicle for aerodynamics, crash, NVH, durability utilizing existing vehicle model database
  • Create unique powertrain, exterior/interior design to fit optimized body envelope
  • Develop prototypes for testing and homologation
  • Launch new vehicle production

28-month vehicle launch process
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Benchmarking

Mule Vehicle Development, Test & Calibration

Optimal has experience developing:

  • Testbed mule electric vehicles equipped with prototype components
  • Evaluation of vehicle controls with EV powertrain
  • Design and build prototype electric vehicle for evaluation

Vehicle Integration, Test & Validation

Optimal Full Vehicle Testing Services utilize some of the industry’s most recognized equipment and software tools to provide our customers with high quality analysis that they need to evaluate competitive products or optimized their own product designs.

vehicle lightweight optimizationEnlarge Image + Optimal offers the following full vehicle testing services:

  • Full vehicle simulation models
  • CAE validation including aerodynamics, durability, crash, safety, NVH, CFD
  • On-Dyno or On-Road performance testing

Award Winning Quality Service & Value

Through the application of the latest technology coupled with a highly experienced, trained and efficient staff, Optimal is the Engineering Services provider of choice for many companies. Optimal is the recipient of the Ford Motor Company Technical Silver Partner Award for their CAE Services.

Optimal maintains its ISO-9001:2008, ISO-14001:2004, is a certified Minority Supplier, and is a member of the Michigan Minority Business Development Council (MMBDC). Optimal was the recipient of the Ford Motor Company Technical Silver Partner Award for their CAE Services.

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