Evaluating the structural strength & thermal performance of electric vehicle battery pack is crucial for enhancing safety & performance. For electric cargo scooter, the battery pack must withstand significant vibrational forces, shocks from impacts & accidental drops all of which can compromise the battery's structural integrity. A failure in this regard could lead to dangerous outcomes such as short circuits, fire, or even explosions, making the robustness of the battery pack crucial for both safety and performance. Conducting physical vibration, shock, and drop tests on a battery pack can result in hazardous situations, necessitating stringent safety measures and specialized equipment, which can be prohibitively expensive and time consuming. The present work focuses on computer-aided virtual simulations at design stage to evaluate the structural integrity, thermal safety & ease of manufacturing of a battery pack assembly, to optimize battery design and reduce prototyping and physical tests. The battery structure was subjected to random vibration and loads using vibration shaker and accelerations/Strain at various locations recorded. Further numerical model was developed using the commercially available finite element (FE) code Abaqus and analyzed against various load cases, including vibration, mechanical shock, and drop tests, in accordance with AIS 156 standards. As the battery is subjected to harsh duty cycle and high ambient temperatures, immersion cooling technology is used to prevent the overheating of the cells. Thermal simulations are performed with various dielectric liquids and compared against air as coolant medium. Most suitable liquid was then experimentally validated against the simulation results. Lastly, we perform injection molding simulations with various variables like material, gate location & process parameters to understand the feasibility of thin-walled structures and overall structural integrity of molded component. Optimal combination was recommended, based on virtual simulations, thus reducing significant cost and time associated with mold rework.