Skywell EV Battery Teardown Review

Understanding the internal design and performance implications of battery systems is critical for engineers, investors, and enthusiasts navigating the electric vehicle landscape. In this teardown, the Munro team walks us through a detailed disassembly of the 72 kWh battery pack from the 2021 Skywell EV SUV Limited. This Skywell EV battery teardown provides insights into design choices, cooling strategies, and manufacturability — crucial elements for evaluating cost and performance in a competitive market.

Introduction to the Skywell Battery Pack

The Skywell battery pack arrives housed in a composite shell — an increasingly popular choice for weight reduction and cost efficiency. This enclosure uses numerous fasteners to maintain rigidity and reduce NVH (noise, vibration, and harshness), including additional fasteners in key areas to prevent oil canning of the lid. Engineers mounted the pack using five primary attachment points on one side and two additional points on the rear. Notably, Skywell applies tamper-evident warranty stickers — an indication of warranty enforcement strategies similar to consumer electronics.

Removal of the battery from the vehicle was straightforward, taking only 30–45 minutes. This ease of serviceability may appeal to fleet operators and service providers looking to minimize downtime. External connections include standard DC voltage outputs, low-voltage interfaces, and coolant line ports for thermal management. The team removed the pack and measured a total voltage of 312 volts, though they still needed to explore the exact module configuration.

Pack Specifications and Performance

This particular unit is rated at 72 kWh with a capacity of 192 amp-hours and an overall weight of approximately 442 kg. In the Skywell ET5 model, the battery delivers an estimated range of 520 km (322 miles). In the version under review — the SUV Limited — range estimates fall between 400–450 km (250–280 miles). These figures place the pack squarely in the mid-tier of EV battery performance for 2021-era designs.

Inside the Pack: Module Configuration and Cooling Design

With the cover removed, the team identified at least five battery modules, with a potential sixth hidden beneath a vertical “tower” structure. The modules are interconnected with bus bars and appear to use a pouch cell architecture. Skywell’s pouches concentrate the anode and cathode on the same end — unlike typical pouch designs — forcing engineers to route series connections creatively.

Each module is outfitted with end-mounted cooling plates. Coolant enters on one side and passes through the stack before exiting on the opposite end. A standout feature is the use of aluminum extrusions to mount the modules, which required the use of abrasive sleeves on bus bars to avoid insulation wear from sharp edges — a lean yet practical workaround.

The battery management system (BMS) interfaces through a top-mounted control hub on the tower, with multiple signal connectors and shunt placements to manage voltage and current flow. FR4 circuit boards extend across module lengths, monitoring individual cell voltages — a layout more typical of low-volume BMS systems.

Potting, Cold Plates, and Thermal Considerations

Where many OEMs place cold plates underneath pouch cells, Skywell opts for side-mounted cold plates that run the entire length of the cells. These are embedded in thermally conductive potting material, presumably for efficient lateral heat transfer. While unconventional, this approach might simplify assembly or accommodate packaging constraints in the vehicle’s underbody.

Engineers vented each module section individually, reflecting their awareness of thermal runaway risk.
These vents are positioned vertically within a plastic shroud, further divided by cell groupings. The design appears modular and serviceable, though not necessarily optimized for automation.

Materials and Manufacturing Observations

Several choices within the pack reflect a low-to-medium volume manufacturing strategy. For instance, the BMS features a hybrid of soldered and screwed connections — a labor-intensive approach compared to automated crimped or welded harnesses used by higher-volume players like Tesla or BYD. Similarly, the pack uses many small screws across both the outer enclosure and internal collectors, again hinting at less robotic assembly.

The choice of aluminum for major structural components helps save weight but adds complexity in terms of insulation and fastener compatibility. Engineers prioritized modularity over manufacturability by using small, individually mounted bus bars and patchy potting patterns.

Electrical Configuration and Voltage Breakdown

With 312 volts measured across the pack and individual modules rated at 45 volts, the numbers don’t quite line up. The expected value for seven modules would be at least 315 volts at 45 volts per module, but this configuration appears to involve some irregularity — perhaps a mix of differently sized modules or unused capacity for future expansion.

The teardown team sought to reduce voltage by removing key bus bars and splitting the pack into electrically isolated sections. This is standard practice when dismantling high-voltage systems, underscoring the importance of safety during teardown operations.

Takeaways: Lean Engineering with Manual Tradeoffs

The Skywell battery pack demonstrates a balanced mix of lean design choices and cost-saving strategies. It’s clearly designed with a mix of serviceability, performance, and budget manufacturing in mind. Notable insights include:

Composite enclosure: Lightweight, corrosion-resistant, and potentially cheaper than stamped steel.
Modular pouch layout: Easy to service but constrained by manual assembly tradeoffs.
Side-mounted cold plates: An unusual choice that may simplify packaging at the expense of thermal efficiency.
Hybrid BMS terminations: Labor-intensive and difficult to automate but potentially more reliable for low volumes.
Tamper-proofing: Warranty voiding stickers may help reduce liability in fleet or consumer applications.

Final Thoughts and Next Steps

While not a groundbreaking design, the Skywell battery pack showcases several clever solutions suitable for mid-market EVs. The focus on manual assembly and repair-friendly layout suggests Skywell is targeting practicality over premium performance. For engineering teams evaluating global battery sourcing or investment opportunities, this teardown provides a window into the types of tradeoffs Chinese OEMs are making in the evolving EV space.

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For more teardown insights, component-level breakdowns, and lean engineering reviews, check us out at Munro & Associates or subscribe to Munro Live. Whether you’re designing the next battery module or evaluating supplier quality, Munro’s expert analysis brings clarity to EV innovation.