What are the key considerations in designing an EV battery pack?

Battery pack design considers: Cell selection and arrangement (series/parallel configuration for voltage/capacity targets), structural integration (floor-mounted, load-bearing capability), thermal management system (cooling plate design, flow paths), electrical distribution (busbars, fuses, contactors), BMS hardware integration, crash protection (maintaining cell integrity), sealing (IP67 or higher for water ingress), serviceability and repair access, and manufacturing assembly sequence. Design must balance energy density, safety margins, thermal performance, and cost while meeting package constraints.