Lightweight battery packs have become a focal point of design, helping engineers extend vehicle range, improve efficiency and reduce overall system weight. As these packs increasingly rely on light alloys and composite materials, the mechanical joints that hold them together face new challenges. This is where wire thread inserts deliver critical value.
Modern battery housings and enclosures are often made from aluminium (accounting for almost 80%), magnesium and advanced composites. These materials provide the strength-to-weight ratio necessary for efficient energy storage, but their mechanical properties differ significantly from traditional steels. Softer substrates are more susceptible to thread wear, stripping and deformation under repeated torque or vibration.
Battery packs face unique environmental and operational demands. Each assembly must withstand cycles of heating and cooling, high vibration from vehicle motion and exposure to humidity and corrosive agents. The joining elements within these packs (bolts, screws, threaded housings, etc.) must therefore maintain precise alignment and integrity over thousands of charge and discharge cycles.
Wire thread inserts provide a durable and reliable solution for fastening within lightweight materials. Installed into tapped holes, these helical coils create a hardened internal thread that distributes load evenly across the fastener. This reduces stress concentration, prevents thread stripping, and enables the consistent reassembly of components without degradation of the parent material.
In electric vehicle battery systems, where compactness and modularity are key, this reliability is vital. Wire thread inserts allow engineers to use thinner walls and lighter housings without sacrificing strength. They also help maintain torque consistency and sealing pressure critical factors for both safety and performance.
Wire thread inserts offer several technical advantages that directly enhance battery pack reliability:
Across the EV sector, manufacturers are prioritising weight reduction to maximise energy efficiency. A lighter battery pack directly improves vehicle range, reduces raw material consumption, and enhances thermal performance. This drive towards sustainability has led to increased use of aluminium alloys and composite housings, both of which rely on wire thread inserts to achieve secure fastening and repeatable serviceability.
Recent industry developments also highlight the growing importance of modular pack designs, where cells and modules must be replaced or reconfigured over the vehicle’s lifespan. Wire thread inserts make this feasible by preserving thread integrity through repeated torque applications and maintenance cycles.
Wire thread inserts are a fundamental enabler of modern lightweight engineering. They transform soft and lightweight materials into robust, serviceable components capable of meeting the demands of electric mobility.
At KATO® Advanex, our Tanged and Tangless coil thread inserts are designed to deliver exceptional strength, corrosion resistance, and thermal stability across all battery and EV applications. Available in multiple materials and finishes, our inserts ensure consistent joint reliability while supporting the industry’s wider goals of performance and sustainability.
To find out more about how our wire thread inserts can support your lightweight battery design, download our guide below.