XD Thermal Launches Integrated Cooling for European Electric Bus Fleet
Suzhou-based XD Thermal has finalized a dual-sided liquid-cooling architecture for European electric bus platforms, trimming component counts by 25 percent. The system, which integrates cooling directly into the battery enclosure, moved from initial prototype to production readiness in just eight weeks, targeting improved thermal management and extended battery lifespan.
The design replaces traditional cooling plates with a multi-interface configuration that manages heat from both sides of the 35.3-kWh battery modules. By unifying the enclosure and cooling functions, engineers simplified assembly and optimized heat distribution. This shift required overcoming complex sealing challenges, as the team had to validate multiple joints simultaneously rather than testing individual components. To ensure reliability, XD Thermal utilized precision fixtures alongside rigorous air and helium-leak testing protocols.
Manufacturing this architecture demanded a departure from uniform coatings. Because different surfaces required specific insulating and thermal-barrier materials, the team engineered custom masking methods to maintain boundary integrity across complex geometries. Technical Director Xu noted that the design boundary now encompasses the entire enclosure rather than just the cooling plate, necessitating a balance between stable thermal performance and practical manufacturing. The company has since scaled this workflow to accommodate various battery-pack dimensions and heavy-duty vehicle requirements, with full volume production capacity operational by the end of 2026.
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