Lightweight battery pack made by additive manufacturing (LAMBADA)
| Reference number | |
| Coordinator | RISE Research Institutes of Sweden AB - RISE |
| Funding from Vinnova | SEK 2 897 035 |
| Project duration | November 2023 - January 2026 |
| Status | Completed |
| Venture | The strategic innovation programme SIP LIGHTer |
| Call | Transnational Eureka Call within Light-weighting Technologies 2023 |
Important results from the project
The project met its initial goals and delivered a lightweight aviation battery pack enabled by generative design and aluminium additive manufacturing. RISE established a precision PBF-LB + post-processing + CNC workflow for AlSi10Mg and the high-strength HS1 alloy, and the frames passed dimensional and structural integrity inspections. Additional outcomes include robust fiber/sensor integration readiness and an LCA showing substantial CO₂ reduction through AM.
Expected long term effects
Long term, the project is expected to accelerate adoption of lightweight, integration-ready battery structures for electrified aviation by proving a scalable generative design + PBF-LB + machining quality chain. This can enable lighter aircraft systems, improved efficiency and safety through embedded monitoring, shorter development cycles, and industrial competitiveness. The demonstrated LCA benefits indicate meaningful CO₂ reductions via near-net-shape AM and lightweighting.
Approach and implementation
The project was executed in structured work packages: WP1 consolidated end-user requirements; WP2–WP3 delivered preliminary and detailed generative design; WP4 established the Swedish manufacturing chain (PBF-LB in aluminium, post-processing and CNC machining, inspection) for AlSi10Mg and HS1; WP5 covered integration and testing in Switzerland; WP6 compiled the development roadmap; and WP7 delivered the LCA. A key deviation was HS1 cracking, handled via added optimization.