Thermal Management for Demanding Applications

A joint commercial EV project between two leading European manufacturers required a custom-designed thermal management system for a newly developed electric platform. The platform was intended for demanding applications, including military-grade and high-load urban usage, and featured high-energy battery systems. The challenge was to deliver a full thermal solution – covering battery, drivetrain, cabin, and auxiliary components – under tight development timelines and strict reliability requirements.

Synchrotek was selected to design and deliver the complete thermal management system, thanks to our track record in high-efficiency control development and system-level integration. Our scope included:

• System architecture definition and control strategy for the entire thermal domain
• Development of custom control algorithms for dynamic thermal balancing across battery, power electronics, and cabin subsystems
• Design and delivery of hardware-in-the-loop capable test stands, focused on battery thermal behavior and control tuning
• Software support and calibration for both prototype validation and series readiness
• End-to-end collaboration with vehicle OEM, battery supplier, and powertrain teams to ensure seamless integration

By combining our expertise in system modeling, test infrastructure, and embedded control, we ensured that the thermal system met both performance and durability requirements.

End-to-end delivery: A fully integrated thermal management system developed from architecture to validation

Custom test infrastructure: Purpose-built test stands for battery thermal control accelerated system maturity

Ready for deployment: The system met the demanding environmental and operational standards required for commercial use, enabling the client to proceed with vehicle integration and pilot deployment