Mahindra has unveiled its new electric vehicle (EV) manufacturing and battery assembly facility in Chakan, Maharashtra. The facility is located within the company’s 2.83 km2 Chakan manufacturing hub, which is a fully integrated, highly automated manufacturing ecosystem to produce its Electric Origin SUVs. The hub leverages over 1,000 robots and multiple automated transfer systems. It is a water-positive facility and is 100% powered by renewable energy.
Mahindra’s Electric Origin SUVs are powered by INGLO battery packs that allow a range of over 500 km. The battery pack uses LFP cells from BYD and is a cell-to-pack design. It adopts blade cell technology.
Blade cells are twice as long as traditional cells and allow use of a single high-voltage pathway instead of three. This increases the space for cells in the battery pack and thus leading to higher power density. The use of cell-to-pack technology, instead of traditional module structures, increases cell space from 66% to 77%, resulting in around 29% higher energy density, as per the company.
“The [new battery assembly unit at Chakan] is one of the world’s most compact battery manufacturing lines, employing patented processes and lean module assembly. This fully automated plant integrates world-class manufacturing processes developed and implemented indigenously to produce, store, and transfer high-performance, long-lasting batteries using industry 4.0 tech,” stated Mahindra.
“The [battery plant] employs a patented pallet design for optimal insulation and geometric accuracy, plus hidden cell terminal welding for enhanced connectivity and robust performance. It performs multi-layered end-of-line testing simulating real-world conditions, backed by IP67 ingress protection, real-time temperature monitoring, and automated anomaly isolation.”
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