Team PackMules have been making way for new battery designs in Year 3 of the Battery Workforce Challenge, and these designs call for unique and precise ways to weld. Thanks to our sponsorship with Hesse Mechatronics, we have the resources necessary to make revolutionary breakthroughs in our battery pack production. Hesse has not only provided the team with industry-leading technology but has also given our members access to real-world processes that expose us to the professional facets of the automotive industry.
This support has been vital since the very beginning of our journey. Hesse helped weld our original prototype and guided us on where we needed to improve our design. Access to their facility has granted us two specific processes that ensure we build the highest-quality battery pack possible while streamlining our production timeline. One of these is a process known as stitch welding, which allows us to bridge two welds together without having to break the connection. Nolan Kelley (VSI Lead) explains the impact: “The stitch welding made it really easy for the team to model the wire bonds without needing to shift individual welds by hand, saving us a ton of time.”
Beyond efficiency, Hesse allows us to use a smaller gauge of wire than other traditional sources for cell welding. Thanks to their ultrasonic welder, we can weld smaller gauges that use less material while acting as a vital safeguard for our battery pack overall. By managing requirements like wire gauge, cell spacing, and welding head positioning, the team is gaining the kind of hands-on experience found in top-tier manufacturing facilities. It has transformed our workflow; instead of working out of a garage on a “homemade” product, we are operating like a professional company producing an official product.
Not only has Hesse impacted our hardware, but also our students’ career development. Every member of our team, from our university students to our vocational students, has been positively impacted by this sponsorship. Ethan Fall (Vocational Lead) emphasizes the importance of this exposure: “The first step in fixing an issue in the automotive world is knowing how the system works. Hesse has provided an ample learning opportunity for our vocational side to get a more in-depth look at the things we will be working with throughout our careers.”
While the battery pack is the heart of the RAM ProMaster EV, the precision of the welds is what keeps that heart beating. The sponsorship from Hesse Mechatronics has turned our design concepts into a physical reality, proving that when student ambition meets industrial-grade resources, the results are electric. We’re not just building a battery; we’re building the expertise needed to lead the next generation of transportation.
The road to the Year 3 final competition is paved with thousands of wire bonds and a lot of PackMules pride. Keep an eye out for the incredible innovation in the automotive industry, and follow our socials—and Hesse Mechatronics—to see the PackMules bring this high-tech build to life!
