Battery modules with casted module enclosures and methods of fabricating thereof

A method of fabricating a battery module, the method comprising:

• die casting an enclosure subassembly comprising a first set of side walls, a second set of side walls, and a second thermal wall;
• friction-stir welding a first thermal wall to the first set of side walls of the enclosure subassembly thereby forming the enclosure, wherein:
• the first set of side walls and the first thermal wall define a first enclosure portion,
• the second set of side walls and the second thermal wall define a second enclosure portion,
• a thermal portion is positioned between the first enclosure portion and the second enclosure portion and is defined, at least in part, by the first thermal wall and the second thermal wall collectively forming a thermal cavity therebetween, and
• positioning a first set of batteries into the first portion such that the first set of batteries is surrounded by the first set of side walls and thermally coupled to the first thermal wall;
• positioning a second set of batteries into the second portion such that the second set of batteries is surrounded by the second set of side walls and thermally coupled to the second thermal wall;
• interconnecting the first set of batteries using a first interconnecting assembly such that, after interconnecting the first set of batteries, the first interconnecting assembly is surrounded and supported by the first set of side walls;
• and
• interconnecting the second set of batteries using a second interconnecting assembly such that, after interconnecting the second set of batteries, the second interconnecting assembly is surrounded and supported by the second set of side walls.