Ariel Nomad 350kW EV Conversion · via Studio Alloy

Integrating an 800V, 350kW drivetrain into an Ariel Nomad

Integrated Cascadia Motion's 800VDC battery system and 350kW drivetrain into an Ariel Nomad chassis - designing the full Power Distribution Unit, owning the master CAD assembly, and performing CNC machining for the project including the decorative battery faceplates.

Role

PDU Design · Master CAD · CNC Machining

Applied

Power ElectronicsCNC MachiningSolidWorksEV Integration

Completed Ariel Nomad EV conversion — FIG 01Completed build - the 350kW conversion outside and driving.

My contribution

Integrated Cascadia Motion's 800VDC battery system and 350kW drivetrain into an Ariel Nomad chassis as the sole engineering team.
Designed the full Power Distribution Unit - precharge circuit, high- and low-side contactors, and current monitoring.
Managed the master CAD assembly for the entire vehicle, including packaging and bracketry.
Performed all CNC machining for the project - including several of the most difficult parts and the decorative battery faceplates.

Objective

The project put a high-voltage, high-power EV drivetrain into a lightweight Ariel Nomad chassis - an 800VDC system delivering 350kW. Our small team of 4 engineers took on designing the high-voltage power distribution, owning the full-vehicle CAD and packaging, and performing all of the project's CNC machining.

Ariel Nomad Power Distribution Unit - high-voltage contactors, copper bus bars, precharge PCB, and current monitoring on a carbon-fiber panel — FIG 02The Power Distribution Unit - high-voltage contactors, copper bus bars for 800VDC current paths, precharge circuit, and control PCB. Designed and assembled in-house.

Decorative battery faceplate being CNC-machined - aluminum panel with diamond pattern geometry in machine with coolant — FIG 03Decorative battery faceplate mid-cut on the 3-axis CNC.

Completed CNC-machined decorative battery faceplate - large aluminum panel with intricate diamond and spiral pattern, fresh off the machine — FIG 04Finished faceplate panel - CNC-machined aluminum, Cascadia spiral logo center, fresh off the machine.

Ariel Nomad mid-assembly - 800VDC Cascadia Motion battery pack installed in the spaceframe with CNC decorative faceplates visible — FIG 05Battery installed with decorative faceplates in place.

Technical details

The Power Distribution Unit handles the high-voltage switching of an 800VDC system: a precharge circuit to safely ramp the DC bus, high- and low-side contactors for isolation, copper bus bars for the main current paths, and current monitoring throughout. The master CAD assembly captured the whole vehicle so battery, drivetrain, and bracketry all packaged correctly. All CNC machining for the project - including the decorative faceplates - was done in-house.

Ariel Nomad near final assembly - complete vehicle in shop on jack stands — FIG 07Near final assembly in the shop - wiring complete, on jack stands for drivetrain checkout.

FIG 08First test drive - the 350kW conversion running under its own power.