Bold takes advantage of the Efficient Multi-Energy Platform industry solution to design and engineer all aspects of its custom high-voltage battery systems for motorsport, marine and aerospace applications. Thanks to the 3DEXPERIENCE on cloud, the company is able to bring its cutting-edge technology to market faster and manage the full product lifecycle with seamless data flow from concept to production.

Accelerating electrification with high-performance batteries

In a state-of-the-art facility overlooking the Circuit de Barcelona-Catalunya racetrack, some of the electrification and aerospace industry’s best minds have come together to push the boundaries of what’s possible in electric vehicle (EV) innovation. They work for Bold Valuable Technology, specialized in the development of high-performance batteries. Many of them, including Bold’s founders, have honed their skills in the fast-paced world of Formula 1 (F1). Now, this impressive team of engineering talent applies the same rigor, energy and speed to scaling electrification technology for aerospace, motorsport and marine applications as it did pursuing driver’s and constructor’s championships.

“Our mission is to make F1 battery technology available at scale so we can electrify mobility for everyone,” said Gerard Torres, chief operating officer at Bold Valuable Technology. “Our backgrounds in F1 mean that we’re used to working at speed to push the boundaries of innovation, and we want to apply that mindset to electrification – on the road, in the air and at sea.”

Creating next-gen battery systems for electric aviation

Bold’s latest battery developments combine cutting-edge cell technology and carbon fiber structural assemblies to create lightweight, highly optimized energy storage systems. They also possess industry-leading thermal runaway containment properties, helping to prevent the onset of thermal runaway – where lithium-ion cells overheat and self-destruct – and contain it should an unexpected event occur. This makes Bold’s energy products ideal for high-performance applications and ideally suited to meet stringent aerospace safety requirements.

Because of the nature of Bold’s work, no two battery packs are the same. The electrification technology team bases each modular design on a pre-selected cell arrangement and then develops the required mechanical packaging and cooling system for each specific use case. All of this work is carried out in CATIA.

“To achieve these high performance and safety requirements, you need to choose the right materials,” said Jon Ander Ferri, senior design engineer at Bold Valuable Technology. “That’s largely down to our knowledge and experience, but CATIA has many functionalities that enhance our work. When we’re producing a plastic injection component, for example, it allows us to check where there is material accumulation and identify where improvements can be made.”

Engineers also benefit from the ability to share their work within the 3DEXPERIENCE platform. It allows them to work concurrently in teams on the same product and easily keep track of modifications.

“When developing the battery enclosure, we make use of the Part Design module in CATIA to create very precise mechanical components,” Ferri said. “We save each one in the platform, so that everyone in the team can access the component and see it in the context of the wider assembly. If we need to make any changes, we can easily access individual components, and any low-level changes are automatically reflected upstream. We can also release the bill of materials directly from the design, removing the risk of human error.”

These efficiencies not only speed up development time, but also help to bring down costs while keeping track of design changes – a critical factor when developing new battery systems for the less mature electric aviation market.

“We have to go through different development stages very fast and maintain traceability for every single component that we’re developing and ultimately launching into production,” Torres said. “With the 3DEXPERIENCE platform, we can push the boundaries of what’s achievable and deliver the best technology to our customers."

Positioned for fast growing

As Bold grows its headcount and takes on bigger, more complex projects, it knows it can rely on the 3DEXPERIENCE platform to help attract new talent and keep its business connected even as it expands beyond its premises in Barcelona.

“It’s a strategic solution for the business on many levels,” Torres said. “The fact you can tell a prospective candidate that you’re using 3DEXPERIENCE and CATIA really helps. Having recently set up a footprint in the UK and looking to expand into the US, the only way we can make everyone work in a seamless, cohesive way is by using the platform.”

Backed by the 3DEXPERIENCE platform, Bold continues to deliver on its vision to make F1 electrification technology available at scale and build on its reputation to become a leader in energy storage solutions for the most demanding applications.

“All businesses exist to serve a purpose, to solve problems for their customers,” Torres said. “We exist to supply the best battery systems so our customers can electrify their fleets and vehicles. It has been critical for us to demonstrate to them that we have the best tools required to develop this cutting-edge technology. From the start, we knew that the 3DEXPERIENCE platform was the right solution for us.”

From the beginning, Bold has relied on its partnership with TECHNIA to provide the technical support its needs as its business continues to grow and evolve. It’s also allowed the company to focus on what it does best: serving its customers’ engineering challenges.

TECHNIA paves the way for innovation, creativity and profitability. The global PLM company is committed to making technology and innovation work in a practical world. This is demonstrated by the resources that it applies to developing exceptional capability in the latest software and process developments. TECHNIA learns before its customers have to, seeking out and identifying the advantages that new products and processes can offer, often within its own business before applying it to its customers.