From Prototyping to Production: Inside Magna's Award-Winning EV Solution

In a small Austrian workshop, a wooden prototype affectionately nicknamed the “waffle maker” emerged as the unlikely hero that led Magna to earn Volkswagen Group’s prestigious Product Award.

From Simple Beginnings to Complex Challenges

When Magna Heavy Stamping embarked on the project in mid-2020, the task seemed straightforward: manufacture and deliver a battery lid frame for Volkswagen Group’s MEB platform. With a clear scope and production to begin in less than two years, our team anticipated smooth sailing.

But as the project progressed, things changed. What started as an easy project quickly evolved in complexity with each new engineering change. The timelines were tight, and the pressure was high, but we stayed focused.

Innovation Under Pressure

In close cooperation with Volkswagen engineers, our team participated in U.S. workshops to support the development and implementation of a thermal propagation fleece. This innovative material acts as a barrier to prevent or mitigate the spread of heat and fire within battery systems, enhancing the reliability and safety of the battery lid frame. By providing heat resistance and fire retardancy, the fleece supports compliance with industry standards.

Back in Austria, the creation of the wooden “waffle maker” prototype was pivotal. Designed in collaboration with our line builder, this tool enabled us to visualize the application of the fleece and served as the foundation for developing a fully automated production line. This line was engineered to deliver 10,000 parts per week, demonstrating our commitment to scalability and efficiency.