How do you design an EV battery enclosure for crash protection while minimizing weight?

Battery enclosure crash design involves: Defining intrusion limits (typically no contact with cells during regulatory and real-world crashes), designing progressive crush zones around battery perimeter, integrating battery frame with body load paths, using high-strength materials (aluminum extrusions, castings) for side rails and cross-members, optimizing bottom plate for ground impact (stones, debris), and managing thermal runaway containment. CAE evaluates multiple crash scenarios (frontal, side, pole, undercarriage). Trade-offs balance weight (affects range) against protection margins. Design must address both crash loads and fatigue from road loads over vehicle life.